Method and apparatus for rotary molding

ABSTRACT

A rotary molding system for molding food products, mold cavities formed when a mold shell rotates mold shapes disposed along the mold shell into a fill position between a fill plate and a wear plate. Molded food products are removed from mold cavities using knock-out cups, the use of air pressure, or the use of a vacuum source disposed below the mold cavity, without the need to slow the rotation of the mold shell. Knock-out cups may be used with a heating system to reduce accumulation of unwanted materials on the knock-out cups. The rotary molding system can also be used to form products with contoured surfaces. A smart tagging system can be used to ensure that compatible sets of mold shells and knock out cups are being used. A vacuum region may be disposed upstream of the fill position to remove air within the mold cavity prior to filling.

RELATED APPLICATIONS

The present application is a continuation of co-pending U.S.Non-Provisional patent application Ser. No. 13/900,970, filed May 23,2013, which is a continuation of U.S. Non-Provisional patent applicationSer. No. 13/187,426, filed Jul. 20, 2011, now U.S. Pat. No. 8,469,697,issued Jun. 25, 2013, which claims the benefit of U.S. ProvisionalPatent Application No. 61/366,033, filed Jul. 20, 2010, the contents ofall of which are incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates in general to molding systems and methods forproducing specifically shaped products, and more particularly, to theproduction of food products.

BACKGROUND OF THE INVENTION

Food patties of various kinds, including hamburgers, molded “steaks,”fish cakes, chicken patties, pork patties, potato patties, and others,are frequently formed in high-volume automated molding machines. U.S.Pat. No. 3,851,355 discloses a meat forming apparatus of the rotatablewheel type. U.S. Pat. Nos. 3,427,649; 4,212,609 and 4,957,425 disclosemethods and machines for producing molded products using a rotary diewith porous bottom walls. Patent Application Publication US 2005/0220932discloses methods for molding three dimensional products from foodstuffs utilizing porous mold cavities. Patent Application Publication US2007/0224306 also provides a method for molding three dimensionalproducts.

U.S. Pat. No. 3,851,355 discloses a meat forming apparatus of therotatable wheel type including a plurality of cavities disposed aboutits peripheral surface. Freely moveable piston means are disposed ineach of the cavities. The pistons move radially outward to reject amolded meat product.

In U.S. Pat. Nos. 3,427,649 and 4,212,609, a rotary die roll with diecavities being defined by a configured side wall and a porous bottomwall is disclosed. During revolution of the roll, a batch of the productis forced into each cavity as the cavity is passed beneath a hopper. Thebottom walls of the cavities are moved outwardly to force the configuredproducts from the die cavities. Air is forced through the porous bottomwalls to assist in the removal of product from the die cavities.

Patent Application Publication US 2005/0220932 discloses the use of aporous structure for the boundary of the mold. The use of a porousstructure with intercommunicating pores allows for uniform distributionof a forcing fluid over all the interfaces between the boundary and themolded product, which assists with the uniform removal of the product.

Patent Application Publication US 2007/0224306 discloses methods andmolding devices for molding three-dimensional products. The methodcomprises filling a mold cavity with a portion of the mass under theinfluence of a filling pressure exerted on the mass, closing the fillingopening of the mold cavity and holding the mass in the mold cavity for afixing period.

The present inventors have recognized that known prior art moldingdevices described, and others, have been disadvantageous for variousreasons. The present inventors have recognized that some machine moldedfood patties exhibit a tendency towards excess shrinkage or distortionwhen the patties are subsequently cooked. The present inventors haverecognized that additional problems encountered in high volume foodpatty molding machines include difficulty in assuring complete andconsistent filling of the mold cavity. The present inventors haverecognized that some of the prior art devices produce molded productslacking the capacity to form uniform molded products efficiently. Thepresent inventors have recognized that frequently, air trapped in a moldcavity as a result of the mold cavity being filled under high pressureleads to non-uniform food products. The present inventors haverecognized that entrapped air also has a tendency to disrupt theejection process, as the force used to push the formed product out ofthe mold cavity is not distributed evenly against the molded product.The present inventors have recognized that filling the mold cavity underlower pressure can allow for air to leave the mold cavity, but fillingthe mold cavity at a lower pressure usually requires an additional stepof applying a fixing pressure in order to produce a cohesive product.The present inventors have recognized that removing air in the moldcavity prior to filling the mold cavity can avoid problems with fillingmold cavities using prior art apparatuses.

The present inventors have recognized the need for a more efficientrotary molding apparatus which produces molded food products withconsistent uniformity. The present inventors have recognized the needfor a rotary molding apparatus that provides for a more efficient anduniform filling of the mold cavities by allowing high pressure fillingwith a mechanism for discharging air trapped in the mold, thus bypassingthe additional step of applying a fixing pressure. The present inventorshave recognized the need for a rotary molding apparatus that providesfor a rotary cylinder with replaceable and removable parts to allow themolding apparatus to accommodate various molding configurations, and toallow the rotary molding apparatus to be easily cleaned and maintained.

The present inventors have recognized the need for a rotary moldingapparatus capable of forming contoured food products.

The present inventors have recognized the need for a rotary moldingapparatus with a mechanism for regulating feed pressure.

The present inventors have recognized the need for more efficientmethods for removing molded food product from the mold cavity.

The present inventors have recognized the need for a rotary moldingapparatus with a tagging system for ensuring that the user utilizes thecorrect knock-out cups with the corresponding rotary mold.

The present inventors have recognized the need for a rotary moldingapparatus with a heating system for preventing buildup around knock-outcup edges.

SUMMARY OF THE INVENTION

The present invention provides a method and apparatus for molding foodpatties that eliminates or minimizes the disadvantages described abovewithout requiring a reduction in the speed of high-volume production ofmolded products.

The present invention provides a method and apparatus for molding foodproducts that consistently conform to the mold cavity configuration.

Accordingly, in one aspect, the invention relates to an improved methodof molding food patties comprising the steps of: feeding pressurizedfood product through a feeder inlet connected to an interface plate,filling a row of mold cavities simultaneously, and providing an outletfor displaced air to escape as the mold cavities are filled. Feederinlets with various mechanisms for evening out filling pressure across arow of mold cavities, such as having more than one inlet, can be used.The interface plate, or fill plate, can also comprise a plurality ofperforations to provide the molded food product with the desiredtextures. The perforated fill plate can be interchangeable with standardfill plates.

A feed pump can be used to feed pressurized food product through thefeeder inlet. In one embodiment, an auger system comprising a pair offeed screws at the bottom of a food hopper transports food product to apump. The output passage of the pump transports food product to thefeeder inlet to fill mold cavities.

In one embodiment, a pump accumulator is disposed between the pump andthe feed inlet to regulate the pressure and/or volume of the food massin the feed pathway. A pump accumulator assists in absorbing anyintermittent increase/decrease in pressure as a result of the feed inletbeing in and out of communication with the mold cavity as the mold shellrotates sets of mold cavities into the fill position. The pumpaccumulator also allows for a more rapid response to a demand for foodmass at a desired fill pressure when a row of new cavities is rotatedinto the fill position in communication with the feed inlet.

Mold cavities rotate in a direction such that the mold cavities firstpass the air discharge region to arrive at the feeder inlet passage. Theair discharge region and feeder inlet passage are situated at a distancesuch that portions of the mold cavity can be in contact with the feederinlet passage and the air discharge region simultaneously. As the moldcavity passes the feeder inlet passage, the food product is depositedinto the mold cavity. As the food product fills the mold cavity, airremaining in the mold cavity is displaced towards the portion of themold cavity that is still in contact with the air discharge region. Theair discharge region provides a route for the air remaining in the moldcavity to escape.

In another aspect, the mold cavity is subjected to a vacuum force toremove air in the mold cavity prior to the mold cavity reaching the fillstation. The vacuum force can be an external vacuum source or be derivedfrom low pressure regions within the rotary molding apparatus.

According to another aspect, the invention relates to an improved rotarymolding system comprising a rotary cylinder that includes a moldcylinder and a cylindrical mold shell wherein the mold shell is disposedaround the mold cylinder and engages with the mold cylinder to form moldcavities. A pair of toothed endless belts in engagement with gear ringsdisposed on either end of the rotary mold cylinder drives the rotarycylinder. Tensioners may be used to enhance the engagement of theendless belt with the toothed gear ring.

The rotary cylinder is disposed against an interface plate having afeeder inlet passage and an air discharge region along a curved surfaceto adapt to the curvature of the rotary cylinder. The mold cylindercomprises rectangular recessed panels which are oriented lengthwisealong the length of the outer surface of the mold cylinder, and isarranged parallel to the horizontal axis of rotation. Air channels areconnected to the back side of the recessed panels.

Fluid, usually a gas, is supplied to the channels from an external fluidsource, and arrives at the surface of the recessed panels via a seriesof interconnected channels. A porous insert is disposed in the recessedpanels. The cylindrical mold shell is disposed around the mold cylindersuch that mold shapes, which are arranged in longitudinal rows along thecircumference of the mold shell, are situated over the porous insertsthat are in the recessed panels. The mold cavity is formed by the moldshape and the porous insert, such that the mold shape forms theconfigured side walls of the mold cavity, the thickness of the moldshell dictates the depth of the mold cavity, and the porous insertsserve as the bottom surface of the mold cavity. The mold cavities openradially.

In another aspect, the invention relates to a method of molding foodpatties comprising feeding pressurized food product to simultaneouslyfill a row of mold cavities. Mold cavities rotate from a fillingposition to an eject position where knock-out cups are used to eject theformed product without the need to stop or slow down the rotary mold.

The rotary molding system can comprise a feeder portion, a fill plate, awear plate, a knock-out mechanism, and a rotary mold with mold shapeswhich form mold cavities when the mold shapes are rotated between thefill plate and the wear plate. The rotary mold comprises mold shapesdisposed around the rotary mold. The rotary mold is a cylindrical shellwith the thickness of the shell corresponding to the depth of the moldcavity. Mold cavities are rotated from a fill position to an ejectposition. As the rotary mold rotates into the fill position, the moldshapes become disposed between the fill plate and the wear plate, withthe surface of the wear plate serving as the bottom surface to the moldcavities as the mold shape rotates through the region where the moldshape is in contact with the fill plate and the wear plate. The wearplate and the fill plate remain stationary as the mold shell rotates.

Once mold cavities are filled, the mold cavities are rotated to an ejectposition wherein knock-out cups are timed with the rotational movementof the rotary mold to knock out molded food products without the need tostop or slow the rotation of the rotary mold. The knock-out mechanismcomprises driving gears which move a movement plate connected inoff-center alignment with respect to driven gears. The off-centeralignment of the movement plate provides a range of motion that istransferred to attached knock-out cups to provide a trajectory whichallows ejection of the molded food product without reducing therotational speed of the rotary mold. In one embodiment, the knockoutcups are used in conjunction with a heating system prevent accumulationof by product such as animal fat, on the edge of the knock out cups.

Other methods of removing the molded food product from a mold cavity canalso be used. In one embodiment, pressurized air in a pressurized airregion in contact with the molded food product can be used to assist inejection of the molded food product. The pressurized air can be suppliedfrom an air pressure source, or can be generated by the sudden movementof a piston within an air pressure region to create a rapid increase or“burst” of pressure. Alternately, the molded food product to be ejectedcan be subjected to a negative pressure from a conveying surface locatedbelow the molded food product in it's eject position.

In another embodiment, the rotary mold is used to generate molded foodproducts with contoured sides. Portions of the fill plate and the wearplate provide the walls of the contoured mold cavity. As the rotary moldrotates into the fill station, the rotary mold comes into contact withthe fill plate and wear plate which are contoured on the surface thatcomes into contact with the rotary mold. The contoured surface of thefill plate and wear plate, together with the mold cavities on the rotarymold, creates a contoured mold cavity. Once the mold cavities arefilled, the contoured molded food product rotates from the fill stationtowards the knock out position, with contoured portions formed againstthe wear plate and fill plate extending above and below the rotary mold,wherein any of the ejection mechanisms can be used to remove the foodpatty from its mold.

In another embodiment, the rotary mold and the knock out cups comprise asmart tagging system such as the use of radio frequency identification(RFID) chips installed to ensure that the rotary mold is being used withthe correct knock out cups. When the rotary mold and knock out cups donot correspond, the molding apparatus will not operate.

Numerous other advantages and features of the present invention will bebecome readily apparent from the following detailed description of theinvention and the embodiments thereof, from the claims and from theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of the rotary molding system of an exemplaryembodiment of the invention.

FIG. 2 is a perspective view of the feeder portion of an exemplaryembodiment of the invention.

FIG. 3 is a perspective view of the interface plate.

FIG. 4A is a perspective view of the interface plate and the feederportion illustrating the back portion of the interface plate.

FIG. 4B is a perspective view of the interface plate and the feederportion, illustrating the front portion of the interface plate.

FIG. 5 is a perspective view illustrating the cross section of thefeeder wall, interface plate, and the rotary cylinder.

FIG. 6 is a perspective view of the rotary cylinder.

FIG. 7 is a perspective view of the mold cylinder.

FIG. 8 is a perspective view of the cross section of the rotary cylinderalong its length.

FIG. 9 is a perspective view of the cross section of the rotary cylinderalong its width.

FIG. 10 is a perspective view of the outer perimeter of the moldcylinder.

FIG. 11 is a perspective view of the mold cylinder with porous insertsdisposed in recessed panels.

FIG. 12 is a perspective view of the mold shell.

FIG. 13 is a perspective view of the rotary cylinder with base ends anda shaft.

FIG. 14 is a perspective view illustrating the motor attached to themolding apparatus.

FIG. 15 is a perspective view illustrating the air inlet region

FIG. 16 is an exploded view of the air inlet end of the rotary cylinder.

FIG. 17 is an exploded view of the rotary molding system or an exemplaryembodiment of the invention.

FIG. 18 is a cross sectional view of the rotary molding apparatus of anexemplary embodiment of the invention.

FIG. 19 is a cross sectional view of the rotary molding apparatus withparts removed for clarity.

FIG. 19A is a cross sectional view of an alternate embodiment of therotary molding apparatus.

FIG. 20 is a cross sectional view of the rotary molding apparatus.

FIG. 21 is a cross sectional view taken along the length of the rotarymolding apparatus

FIG. 22 illustrates the trajectory of the knock out cups.

FIG. 23 illustrates a pivoting mechanism for the rotary mold.

FIG. 24 A, B illustrates a pivoting mechanism for the rotary mold.

FIG. 25 illustrate the attachment of the knock out cups to the movementbar.

FIG. 26 illustrates the fill plate.

FIG. 27 illustrates another embodiment of the rotary mold being rotatedusing a belt.

FIG. 28 illustrates the knock out mechanism within the rotary mold whena motor is used to rotate the mold.

FIG. 29 illustrates a cross sectional view of an alternate embodiment ofusing pressure to remove a molded food product.

FIG. 29A illustrates a perspective view of implementing the methodillustrated in FIG. 29, with portions removed for clarity.

FIG. 30 illustrates a top view of an exemplary embodiment of a fillplate comprising two feeding channels.

FIG. 31 illustrates a cross sectional view of an exemplary embodiment ofa rotary molding system where the mold cavities are subjected to a lowpressure region prior to filling.

FIG. 32 illustrates a perspective view of an alternative embodiment of afill plate comprising perforations.

FIG. 33 illustrates an alternate perspective view of the embodiment ofFIG. 32.

FIG. 34 illustrates the view of FIG. 33 with parts removed for clarity.

FIG. 34A illustrates a perspective view of a fill plate comprising afill slot.

FIG. 34B illustrates an alternate perspective view of the embodiment ofFIG. 34A.

FIG. 34C illustrates an exemplary embodiment of the rotary moldingsystem comprising tensioners.

FIG. 34D is an elevation view of an exemplary rotary molding machineshowing tensioners held in place by supports, which are supported by asupport frame.

FIG. 35 illustrates an alternate embodiment of a mechanism for removingmolded food product from the rotary mold.

FIG. 35A illustrates the translation of rotational motion into linearmotion for actuating a piston rod.

FIG. 35B illustrates mold cavities of various shapes disposed within theair pressure region.

FIG. 35C illustrates an alternate embodiment for actuating the pistonrod.

FIG. 35D illustrates an exemplary embodiment for operating the pistons.

FIG. 35E illustrates yet another embodiment for removing molded foodproducts from the mold cavity.

FIG. 35F is a close up view of portions of FIG. 35E.

FIG. 36 is a perspective view of an exemplary embodiment of a rotarymolding apparatus for contoured food products.

FIG. 37 is a side view of the fill plate of FIG. 36.

FIG. 38 is a side view of the wear plate of FIG. 36.

FIG. 39 is a view of the rotary mold in FIG. 36 as seen along line39-39.

FIG. 40 is a view of the rotary mold in FIG. 36 as seen along line40-40.

FIG. 41 is a perspective view of a contoured molded food product.

FIG. 42 is a side view of the rotary molding system of FIG. 36.

FIG. 43 is a side view of an alternate embodiment of the rotary moldingapparatus for forming contoured food products.

FIG. 44 is a longitudinal cross section view of the rotary mold forforming contoured food products.

FIG. 45 illustrates a side view of one embodiment of the rotary moldingsystem using a pair of feed screws to transport food product to a rotaryfood pump.

FIG. 45A illustrates a top view of the embodiment of FIG. 45.

FIG. 45B is an enlarged side view of the pump of FIG. 45.

FIG. 46 is a top side view of the rotary pump with the face plateremoved.

FIG. 47A is an inlet side view of the rotary food pump.

FIG. 47B is an outlet side view of the rotary food pump.

FIG. 47C is a perspective view of a rotor from the rotary food pump.

FIG. 47D is a top side view of the rotary food pump.

FIG. 47E is a schematic diagram of a portion of the rotary pump.

FIG. 47F is a wing of the rotor within a portion of its area inoperation.

FIG. 48 is a bottom side view of the rotary pump with the back plateremoved.

FIG. 49 is a perspective view of a rotary pump motor.

FIG. 50 is a side view of one exemplary embodiment of the meataccumulator.

FIG. 51 is a cross sectional view of the meat accumulator of FIG. 50.

FIG. 52 is a schematic diagram of the signal control for the pumpaccumulator system

FIG. 53 is a cross sectional view of the front side of the heatingsystem.

FIG. 53A is a cross sectional view of the back side of the heatingsystem as seen from the external manifold.

FIG. 54 is a side view of the RFID sensor system for the knock out cupbar.

FIG. 55 is a top view of one exemplary embodiment of the heating regionof the heating system.

FIG. 56 is a top view of the heating system of FIG. 55 illustrating oneexemplary embodiment of the arrangement of the heating tubes.

FIGS. 57A-57C illustrates the progression of removal of molded foodproduct from a mold cavity by one embodiment of the air knife system.

FIG. 57D is an enlarged view of FIG. 57B.

FIG. 58 illustrates a side view of an air knife.

FIG. 59 illustrates one embodiment of the air knife system used incombination with a vacuum chamber disposed below the molded food productto remove the molded food product.

FIGS. 60-63 illustrate various embodiments of a food product removalsystem having a vacuum chamber disposed below the rotary mold.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While this invention is susceptible of embodiment in many differentforms, there are shown in the drawings, and will be described herein indetail, specific embodiments thereof with the understanding that thepresent disclosure is to be considered as an exemplification of theprinciples of the invention and is not intended to limit the inventionto the specific embodiments illustrated.

FIG. 1 illustrates the primary components of an embodiment of a rotarymolding system. The rotary molding system comprises a food feederportion 100, an interface plate 200, a mold cylinder 300, and a moldshell 400. The food feeder portion 100 utilizes a pumping mechanismenclosed in a pump box 120 to feed pressurized food product though thefeeder inlet 130 for deposition into the mold cavities. The interfaceplate 200 adapts the feeder portion 100 to the curvature of the rotarycylinder, which is comprised of the mold cylinder 300 and the mold shell400.

The various components of the invention will now be discussed in detail.

The Feeder Portion

FIG. 2 illustrates the feeder portion 100 of the rotary molding systemwhich is used to supply food product into mold cavities situated on thesurface of a rotary cylinder. The feeder portion 100 comprises a foodhopper 110 connected to a pump box 120. In the embodiment shown, thepump box 120 is situated below the food hopper. In other embodiments,the pump box can be in a different location such as, for example,behind, in front of, or adjacent to, the food hopper, depending on theconfiguration desired and the type of pumping mechanism used. In oneembodiment food product is continuously delivered to the food hopper 110such that the level of food in the food hopper is maintained constant,and allows for delivery of food product of a pre-determined pressureinto the mold cavities. The pump box contains an extruder. Othersuitable pumping devices can also be used.

Food product is pumped from the food hopper 110 to the feeder inlet 130.Food product can be pumped at a constant and continuous pressure as themold cylinder rotates past a feeder inlet passage 210 (FIG. 3).Alternatively, the pumping mechanism can be controlled such that foodproduct is only pumped through the feeder inlet passage 210 when atleast a portion of the mold cavity has reached the feeder inlet passage.

The feeder portion 100 of the rotary molding system is made from a rigidmaterial such as a metal or metal composition. The feeder inlet 130 isan opening in a feeder wall 160 which is rigidly connected to the pumpbox 120 and food hopper 110, and is situated generally perpendicular tothe direction of food product flow.

The wall is of a thickness sufficient to support the weight of the foodhopper 110, pump box 120, and food product, as well as withstand theforce of the pressure of the food product being pumped through thefeeder inlet 130. In one embodiment, the food hopper 110, pump box 120and feeder wall 160 are made from one continuous piece of material. Inother embodiments, the food hopper 110, pump box 120, and feeder wall160, or a combination of thereof, are separately manufactured andconnected. In the embodiment illustrated in FIG. 2, an air dischargeoutlet 140 is situated below the feeder inlet 130. The feeder inlet 130and the discharge outlet 140 open onto a planar surface 150 on the sideof the feeder wall facing away from the food hopper 110 and pump box120. The discharge outlet 140 is connected to a discharge outlet channel141 which diverts air away from the feeder portion. The feeder wall 160is rigidly attached to the interface plate 200 via screws or otherconnecting mechanisms.

In one embodiment, as illustrated in FIG. 45, the feeder portion 2300comprises a hopper 2025 and an auger system 2400 connected to a pumpintake passage 2310, a rotary pump 2330, and a pump output passage 2316.A pump motor 2350 drives the pump 2330.

The auger system 2400 is located at the bottom of the hopper 2025. Theauger system includes two feed screws 2402, 2404, and two feed screwdrive motors 2406, 2408 (FIG. 45A). The feed screws 2402, 4204 each havea center shaft 2410, 2412. The center shafts are journaled in andsupported by front and rear feed screw supports 2414, 2422. The feedscrew supports extend vertically from and attach to the machine base2021. The feed screws are located adjacent to one another and extendlongitudinally along the bottom of the hopper. The center shafts areparallel to the bottom 2527 of the hopper.

As shown in FIGS. 45 and 45A, the rear 2025 c of the hopper has anopening that is covered by a cap 2530. The cap 2530 has holes 2531 thatthe feed screw shafts are journaled to rotate therein on bearings. Theshafts extend through the cap to connect to the motors 2408, 2406. Therear opening of the hopper has a vertical lip 2529 a. The back of thecap has a recessed portion 2530 a that mates with the lip 2529 a. Thecap also has a non-recessed portion 2530 b that fits into the rearopening.

A hopper outlet 2532 is formed to or attached to the front 2533 of thehopper 2025. A portion of the outlet opening is aligned with the bottomfloor 2527 of the hopper. The outlet extends forward of the main hopperbody 2025 a as shown in FIG. 45A. The outlet has a connecting section2534 and a narrowing section 2535 that narrows to an outlet flange 2536toward the food pump system 2300. The outlet has a width that is greaterthan its height. Upper and lower feed screw supports 2420, 2421 extendfrom the conical section 535 to a bearing head 2422 a. The supports2420, 2421 are perpendicular to the conical section 535 inside surfaceand extend therefrom to an elbow and bearing sleeves. The front of theshafts 2412, 2410 have a recessed portion 2425 that terminates in aconically reducing point end 2424. The point end 2424 extends beyond thebearing sleeves. The shafts 2410, 2412 are journaled to rotate at thefront on the recessed portion 2425 in the bearing sleeves. As shown inFIGS. 45 and 45A, the front portion of the feed screws are enclosed bythe outlet 2532 and extend beyond the main hopper body 2025 a. Theoutlet 2532 is connected to the inlet of the pump.

The rotary pump 2330 is show in detail in FIGS. 46-48. The rotary pumpcan be an Universal I Series Positive Displacement Rotary Pump, modelnumber 224-UI with a rectangular outlet flange manufactured by WaukeshaCherry-Burrell, with a place of business in Delavan, Wis., andaffiliated with SPX Flow Technology.

As shown in FIG. 46, the pump 2330 has a housing with a pump area 2332 aand a gear area 2332 c. The pump has an inlet 2334 and an outlet 2338 incommunication with the pump area 2332 a. The pump area is separated fromthe gear area by a wall 2332 d. A portion of the gear area is shown inFIG. 48 were the back cover plate is removed. A drive gear 2364 and adriven gear 2365 are meshed across a meshed arch of each gear 2356 a,2364 a. The drive gear is keyed to rotate in sync with the drive shaft2360 at a first end of the drive shaft. The drive gear has a locking nutand lock washer 2361 that assists in securing the gear to the driveshaft. The driven gear is keyed to rotate the driven shaft 2363. Thedriven shaft has a locking nut and lock washer 2362 that assists insecuring the gear to the driven shaft at a first end of the drive shaft.The driven and drive shafts are journalled through a support structure(not shown) in the housing to carry rotors 2340 a, 2343 a at second endsof the driven and drive shafts opposite the first ends. The supportstructure (not shown) in the housing contains high capacity, doubletapered roller bearings that the drive and driven shafts rotate on. Therear cover plate (not shown) contains an opening to allow the driveshaft to extend outside of the housing to engage a drive source such asthe motor 2350.

The second ends of the drive and driven shafts have a splined section(not shown). The rotors 2340 a, 2343 a have a splined opening that mateswith the splined section of the drive and driven shafts respectively.Each rotor 2340 a, 2343 a has two lobes or wings 2340, 2341 and 2342,2343, respectively. The wings have overlapping areas of rotation asshown in FIG. 47E. Each wing is located opposite the other wing on therotor and gaps are located between the wings about the circumference ofthe rotor. The wings travel in annular-shaped cylinders 2339 c (notlabeled for rotor 2340 a) machined into the pump body. The rotor isplaced on the shaft with a plate portion 2344, 2345 outwardly facing.Nuts 2348, 2349 are screwed on a threaded end portion of the shafts tosecure the rotor in place. The rotors have a close fit clearance betweenthe outer surface of the wing 2343 a and the corresponding wall faces2339 c of the pump area. As shown in FIG. 47E, the wing of one rotorwill be located in the open area of the other rotor during a portion ofan operation cycle. An operation cycle comprises a full 360 degreerotation of a rotor.

The splined mating of the rotors and shafts ensure that the rotorsrotate in sync with the respective drive and driven shafts. The rotorsare interference fitted in the pump area as shown by their overlappingareas of rotation. The gearing 2365 a, 2364 a prevents the rotors fromcontacting each other during operation.

When the drive shaft 2360 is rotated in direction C shown in FIG. 48,the drive shaft rotates the first rotor in the same direction, directionA in FIG. 46. Simultaneously, as provided by the meshed gearing 2364,2365 the second rotor is rotated in the opposite direction, as shown bydirection B in FIG. 46, of that of the first rotor.

The pump area 2332 a face 2339 a is covered to enclose the pump area bya face plate 2332 (FIG. 47 A). The face plate has raised areas 2323 a,2323 b for accommodating space required for the shaft ends and thecorresponding nuts 2348, 2349. The face has a plurality of holescorresponding to the studs 2339 that extend from the face 2339 a. Faceplate wing nuts 2333 secure the face plate to the face 2339 a.

The outlet 2338 is a circular outlet and the inlet 2334 is a rectangularinlet. The inlet 2334 has corresponding rectangular flange 2337 with theoval seal or gasket 2336. The outlet let 334 connects pump outputpassage 2316.

The pump 2330 is driven by the pump motor 2350. The motor is shown inFIG. 49. In one embodiment, the motor 2350 is a servo rotary actuator,such as the TPM+Power 110 Stage 2 series rotary actuator with brakemanufactured by Wittenstein, Inc. with a place of business in Bartlett,Ill. In one embodiment motor 2350 is an electric servo rotary actuator,such as the model TPMP110S manufactured by Wittenstein, Inc. The servorotary actuator comprises a combined servo motor and gearbox assembly inone unit. The servo rotary actuator has a high-torque synchronous servomotor. The configuration of the servo motor and the gearbox gearingprovides the actuator with a reduced length. The actuator has ahelical-toothed precision planetary gearbox for reduced noise and quietoperation.

The motor 2350 has a housing 2351, an electrical connection 2351 b, amounting face 2315 b, and an output coupling flange 2358 b. The mountingface 2315 b has a plurality of holes 2315 a. As shown in FIG. 45B, thepump is secured to a mounting plate 2311 by a plurality of bolts 2311 awhich engage the back of the pump, such as by engaging threaded holes(not shown) at the back of the pump. The mounting plate 2311 is securedto the machine base 2022 by bolts 2312. A circular mounting member 2313encloses the connection between the motor and the pump and attaches tothe mounting plate 2311. Alternatively, the mounting member 2313 mayconnect directly to the machine base. The mounting member 2313 connectsto the motor 2350 at the mounting face. A number of bolts 2315 securethe motor to the mounting member. A circular coupling 2356 is attachedto the output coupling flange 358 b by bolts 2358 threaded into thecorrespondingly threaded holes 358 a of the output coupling flange 358b. At an opposite end, the coupling 2356 receives the drive shaft 2360in an opening of the coupling 2356. The drive shaft has a key 2360 a(FIG. 47A) that engages a corresponding slot of the opening of thecoupling 2356 to lock the pump 330 to the coupling 2356, The motor isangled to align with the output shaft of the pump.

In operation, food product in the hopper 2025 is transported towards thepump 2330 via the pair of feed screws 2402, 2404. The pump 2330 andmotor 2350 are disposed in vertical alignment with respect to thehorizontal direction of travel of the food product from the hopper, tothe food pump, and into the outlet passage towards the rotary mold.

The output passage 2316 of the pump is diverted into two branches 2316a, 2316 b. The two branches 2361 a, 2361 b extend toward a feederportion 2700 with two feeding channels 2710. Each branch 2361 a, 2361 bsupplies a source of food product to a feeding channel 2710 through thefeeding channel inlets 2706. The output passage 2316 may divert intomore than two branches, to supply a source of food product to multiplefeeding channels. Alternately, the output passage may be one continuouspassage that supplies a source of food product to one feeding channel.

Pump Accumulator

In one embodiment of the food patty molding apparatus illustrated inFIG. 50, a pump accumulator system 3000 is disposed between the foodpump 2330 and the feed plate 2703. The pump accumulator system 3000comprises a passageway through which food product from the food pump2330 passes to the feed plate for filling the mold cavities. Thepassageway is a cylindrical chamber 3010 which connects the pump outletchannel 3011 to the feed plate inlet channel 3012. A portion of theexterior of the cylindrical chamber 3010 is surrounded by a housingstructure 3030, generally located in the middle of the cylindricalchamber. The housing structure 3030 is a two piece structure comprisingan upper housing 3030 a and a lower housing 3030 b, arranged to fitabout the curvature of the cylindrical chamber. The housing structure3030 can be made from aluminum, or any other suitable metal, or plastic.The upper housing 3030 a and lower housing 3030 b are connected aroundthe circumference of the cylindrical pathway by bolts 3033. The lowerhousing comprises a pressure channel 3020 in communication with thecylindrical chamber 3010, and extends perpendicularly downward from thecylindrical chamber 3010. A seal 3011, such as a rubber O-ring, isdisposed at the intersection of the pressure channel 3020 and thecylindrical chamber 3010.

A pressure chamber 3031 is connected to the lower housing 3012 at thebase of the lower housing. The pressure chamber 3031 can be made from aplastic material, or any other suitable material can also be used. Apiston 3060 is disposed in connection with both the pressure chamber3031 and the pressure channel 3020. Piston 3060 comprises a pressurechamber surface 3061 which moves within the pressure chamber 3060.Piston 3060 also comprises a pressure channel surface 3062 which moveswithin the pressure channel 3020. The surface area of the pressurechannel surface corresponds to the cross sectional area of the pressurechannel. The surface area of the pressure chamber surface corresponds tothe cross sectional area of the pressure chamber. In the embodimentillustrated, the pressure chamber has a greater cross sectional areathan the pressure channel. In one embodiment, the ratio of surface areaof the pressure chamber surface to the piston channel surface is 3:1.Any other ratios can also be used to generate a greater pressure at thepressure channel surface.

The pump accumulator allows for the volume of food mass and/or thepressure of the food mass disposed between the food pump and the feedinlet to vary as needed. Food mass is pumped into the fill plate forfilling the mold cavities at a desired pressure. Once filled, the moldcavities are rotated away such that the next row of mold cavities can befilled. In the time between the arrival of the next row of empty moldcavities, the pump continues to pump food mass into the region betweenthe food pump and the feed inlet. Pending the arrival of the next row ofempty mold cavities, the feed inlet is temporary not in communicationwith the mold cavities. As such, the region upstream of the feed inletmay experience intermittent, repetitive surges of pressure which cancause undue wear on the rotary pump over time.

In one embodiment, the pump accumulator allows for the absorption of thefluctuation in the pressure and/or volume of the food product as it isbeing fed from the pump into the mold cavities. The pump accumulatoralso serves as a reservoir for food mass and provides for increasing thefill pressure to the desired fill pressure as needed when a new row ofempty mold cavities arrives at the fill position. By providing areservoir volume of food mass on hand to minimize drops in pressure dueto the arrival of an empty row of mold cavities, the pump accumulatorassists in achieving the fill pressure in less time, thus enhancing theefficiency of the fill process.

The volume of food mass in the pump accumulator and/or the pressure ofthe food mass can be adjusted by moving the piston upwards or downwardswithin the pressure channel. Downwards movement of the piston increasesvolume in the pump accumulator due to the additional volume created inthe pressure channel. Upwards movement of the piston within the pressurechannel decreases the volume within the pump accumulator.

The position of the piston can be moved by increasing the pressure inthe pressure chamber disposed below the piston. As pressure increases inthe pressure chamber, the piston is urged upwards. To move the pistondownwards, the pressure in the chamber is decreased to decrease theforce exerted on the pressure chamber surface side of the piston.Pressure is exerted on the pressure chamber surface 3061 of the pistonby the delivery of gas, such as air, or other fluid, into the pressurechamber 3031. Gas delivery into the pressure chamber 3031 is by way ofan inlet channel 3063 which can be connected to a source of fluid, suchas an oxygen tank. A pressure regulator 3600 (FIG. 52) regulates thedelivery of gas into the pressure chamber. To maintain a tight sealbetween the piston and the pressure chamber, and between the piston andthe pressure channel, seals 3035, 3036, such as rubber O-rings, can beused.

To gage the position of the piston, and thus the volume of food productwithin the pump accumulator, a linear displacement transducer can beused to determine the vertical position of the piston. The transducer3070 comprises a stationary probe 3071 which senses the position of amagnet, such as a magnet 3072 disposed on the bottom of the piston justbeneath the pressure chamber surface of the piston. The transducer 3070senses the displacement of the piston along a distance “D” andcommunicates the displacement information to a computer or other controlsystem component. The control system calculates the amount of foodproduct accumulating in the pump accumulator and determines whether thevolume of the food mass accumulating in the pump accumulator is within adesired range, at a given pressure. A pressure sensor 3001 is disposedon top of the pump accumulator, with access into the cylindrical chamberto determine the pressure of the food mass in the pump accumulator. Thepressure sensor is secured in place within the upper housing.

FIG. 52 illustrates in schematic fashion the control system of the pumpaccumulator system. The pump motor 2350 drives the pump 2330 to deliverpressurized product, such as ground or comminuted meat, into theaccumulator and also into the mold cylinder 300. A pressure sensor 3001located between the pump and the mold, such as on top of the accumulatorsends a pressure signal. The pressure signal is compared to a desiredproduct pressure setpoint 3510 that is pre-determined and input, at anerror module 3512 of a central processing unit. The error module 3512issues an error signal 3513 representative of the difference between thedesired product pressure setpoint and the actual product pressure, usinga percent error, PID correction calculation, to a summing module 3514.The summing module 3514 receives a speed signal 3516 from a pump motorspeed sensor 3517 and issues a pump speed command signal 3518 based onthe current speed of the pump motor and the error signal from the errormodule 3512. This control will adjust the pump motor speed to increaseor decrease the pump output pressure of the product based on the actualproduct pressure sensed and the desired product pressure setpoint.

The product pressure signal from the pressure sensor 3001 is also sentto a control module 3522. Since the ratio between the areas of thepressure chamber surface 3061 and the pressure channel surface 3062 is aset value, the control module 3522 can use the product pressure signalto determine an equivalent air pressure setpoint within the pressurechamber 3031 based on the ratio of the piston areas.

However, according to the exemplary system, not only is pressure in thechamber controlled but also the position of the piston is controlled toset the piston sufficiently retracted, or low in the verticalarrangement shown, to ensure that sufficient product is contained withinthe pressure channel during operation to dampen pressure fluctuation dueto the rapid depletion of the food product within the channel 3020during mold cavity filling and subsequent closing of mold cavities asthe rotary mold rotates. An air pressure signal from an air pressuresensor 3526 sensing pressure in the pressure chamber 3031 is sent to asumming module 3528. A piston position signal from the transducer 3070is also sent to the summing module 3528. The control module 3522 sends acommand signal to a pressure regulator 3600 that receives a source ofhigher pressure compressed air 3602 and throttles this air for deliveryof pressure controlled, pressurized air into the chamber. The summingmodule 3528 executes a calculation to ensure that the position of thepiston is within a desired range to ensure sufficient product within theaccumulator and then ensures a corresponding correct pressure within thechamber to ensure minimal fluctuation in product pressure duringfilling/non-filling of the rotating rotary mold.

The modules referred to above can be: an application-specific integratedcircuit (ASIC) having one or more processors and memory blocks includingROM, RAM, EEPROM, Flash, or the like; a programmed general purposecomputer having a microprocessor, microcontroller, or other processor, amemory, and an input/output device; a programmable integrated electroniccircuit; a programmable logic device; or the like. The modules can beincorporated into the central machine controller.

Interface Plate

The interface plate 200 in FIG. 3 adapts the flat surface 150 of thefeeder wall 160 to the curvature of the rotary cylinder 299 shown inFIG. 6 so as to allow the food product to be deposited into the moldcavities as the rotary cylinder rotates. As illustrated in FIG. 3, theinterface plate comprises the feeder inlet passage 210 and air dischargeregions 220. As illustrated in FIG. 4A, the feeder inlet passage 210 hasa front opening 211 which comes in contact with the rotary cylinder, anda back opening 212 which comes in contact with the planar surface 150 ofthe feeder wall 160. In some embodiments, the feeder inlet opening 130is substantially the same width, height and shape as the back opening212 of the feeder inlet passage 210, as shown in FIG. 4A. The frontopening 211 can be smaller than the back opening 212, as shown in FIG.4A. In other embodiments, the back opening of the feeder inlet passagecan be smaller, larger, or of a different shape than the feeder inlet130, and the front opening 211 and back opening 212 can be of the same,smaller, larger, or of a different shape from one another, depending onthe desired pressure of the food product and other processingparameters.

In one embodiment as illustrated in FIG. 3, the air discharge region 220comprises an arrangement of holes. The holes allow for air to escape themold cavity as food product fills the mold cavity and displaces the air.The holes are arranged in rows which form three columns, with eachcolumn corresponding to the position of the mold cavities on the rotarycylinder. Other arrangements of the holes of the air discharge regioncan be used to suit various mold cavity arrangements.

In the embodiment illustrated in FIG. 3 and FIG. 4B, the interface platecomprises a central region 230. The front opening 211 of the feederinlet passage 210, and the air discharge region 220 are situated withinthis central region. The central region is a generally rectangularregion on the interface plate that spans a length “a” 231 across theinterface plate, and length “h” 232 along the curved surface of theinterface plate, and protrudes from the interface plate. The protruding,curved central region protrudes from the curved interface plate in adirection towards the rotary cylinder, and is the portion of theinterface plate that comes in contact with the rotary cylinder.Providing a protruding region in contact with the rotary cylinder allowsfor the apparatus to minimize friction, by ensuring that only thecomponents on interface plate necessary for filling the mold cavitiesduring the operation of the apparatus, such as the feeder inlet passageand the air discharge region, is in contact with the rotary cylinder.The length “a” 231 of the central region 230 of the interface plategenerally corresponds to the distance a row of mold cavities spans alongthe length of the mold cylinder 300. In other embodiments, the centralregion does not protrude, and the entire interface plate comes incontact with the rotary cylinder.

FIG. 5 illustrates two air discharge channels 233 connected from behind,to the holes in the air discharge region 220 such that discharged airflows through the air discharge channels 233 in the interface plate 200and exits the interface plate 200 via two back openings 222 illustratedin FIG. 4A. The back openings 222 are situated such that when the planarsurface 150 of the feeder wall is in contact with the interface plate200, air exiting from the back openings 222 flows into the dischargeoutlet 140, where it leaves the feeder portion via the discharge outletchannel 141 (FIG. 4A). Other arrangements of air channels can be used,to provide for adequate structural support of the interface plate at theair discharge region 220 to prevent structural deformations or otherissues due to pressure at the air discharge region 220.

The thickness of the interface place at the air discharge region 220 isof sufficient thickness to withstand pressure from air and feederproduct, for example, generally ⅙″ to ¼″, with thickness varying withthe type of material used. The holes are of suitable size and allow airto escape the mold cavity, and yet prevent significant amounts of foodproduct from passing through the holes. As illustrated in FIG. 4A, thesurface on which the front opening 211 of the feeder inlet passage 210and the air discharge region are situated is a curved surface, with thecurvature of the surface corresponding to the curvature of the rotarycylinder.

The air discharge region 220 and feeder inlet passage opening 211 aresituated at a distance such that portions of the mold cavity can be incontact with the feeder inlet passage opening 211 and the air dischargeregion 220 simultaneously. In operation, the rotating mold rotates in adirection such that the mold cavities first come in contact with the airdischarge regions 220, and then with the feeder inlet passage opening211. As the mold cavity rotates past the feeder inlet passage opening,food product simultaneously fills the mold cavity and displaces the airremaining in the mold cavity. Because a portion of the mold cavity isstill in contact with the air discharge region as the mold is beingfilled with food product, the displaced air leaves the mold cavity viathe holes in the air discharge region 220. The displaced air flowsthrough the holes in the air discharge region 220, and into the airdischarge channels 233, where it is connected to the discharge outlet140 and exits the apparatus via the discharge outlet channel 141. As themold cavity passes the feeder inlet passage opening 211 which fills themold cavity, the mold cavity rotates past an area of the interface platethat allows the mold cavity to close at least partially, if notentirely, and allows the patty to settle and form its shape. The mold isfilled with food product at a sufficient pressure such that theapplication of fixing pressure is optional, but not necessary.

FIG. 5 illustrates an embodiment where the feeder portion 100 issituated to the side of the rotary cylinder 299, such that the moldcavities are filled when the mold rotates to approximately the nine'oclock position. In alternate embodiments, the mold can be filled whenthe mold cavities are in a different position, such as when the moldcavities are in the twelve'o clock position. The feeder portion can besituated anywhere relative to the rotary cylinder, for example, such asabove the rotary cylinder, to fill the mold cavities from above therotary cylinder. Alternatively, the feeder portion can be situatedhorizontally adjacent to the rotary cylinder, yet adapted to feed foodproduct into the mold cavity from above the rotary cylinder.

The position on the rotation where the mold cavity is filled can bedependent on various factors with which persons skilled in the art wouldbe familiar, such as the type of the food product to be molded, thefixing time of the food product, the amount of time the product shouldremain in a closed food cavity, and where along the rotation the productis to be ejected.

FIG. 5 also illustrates an embodiment of the rotary molding apparatuswherein the interface plate is in contact with a portion, for example25%, of the surface of the rotary cylinder. After passing the feederinlet passage, the interface plate can provide additional contact withthe rotary cylinder so as to allow the mold cavity to remain fullyclosed for a desired duration of time. In other embodiments, theinterface plate can come in contact with a higher percentage of thesurface of the rotary cylinder, such as about 30% to 50%, depending onthe shape of the mold cavities, or depending on whether mold cavitiesneed to remain closed for a longer amount of time as the pressurizedfood product is fixed in the mold cavities.

In one embodiment, the interface plate can provide more than a feederinlet passage, an air discharge outlet, and temporary mold closure. Theinterface plate can also cover a greater portion of the rotary cylinderso as to provide additional processes, such as feeding an additionallayer into the mold cavity, providing a surface treatment, cleaning, orpre-treating the mold cavity surface prior to filling the mold cavity.The percentage of rotary cylinder surface in contact with the interfaceplate can be optimized by taking into consideration the desiredfunctions as well as the increased friction as a result of an increasein surface area contact.

Mold Cylinder

The rotary cylinder 299 as seen in FIG. 6 comprises the mold cylinder300 and the mold shell 400. The mold cylinder 300, as illustrated inFIG. 7, comprises rectangular recessed panels 310 which are orientedlengthwise along the length of the mold cylinder parallel to ahorizontal axis of rotation (not shown).

Fluid, usually gas such as air that is preferably compressed, issupplied from an external fluid source. Fluid is delivered to thesurface of the recessed panels 310 via a series of interconnectedchannels comprising main channels 320 which branch off into smallerchannels 330, as illustrated in FIGS. 8 and 9. The smaller channels 330are of suitable channel diameter, length, and angle to deliver desiredlevels of fluid at appropriate pressure to the recessed panels 310. Inother embodiments, the smaller channels can be further branched so thatadditional channels are delivering fluid to the recessed panels.

The main channels 320, as illustrated in FIG. 8, are situatedlengthwise, and in parallel to a horizontal axis of rotation of therotary cylinder. Air is delivered to the main air channels by providingan air inlet region 600 that is stationary relative to the rotarycylinder 299, as illustrated in FIG. 15. The air inlet region 600comprises a supporting plate 602, two brackets 605 (FIG. 16), an airinlet tube 608, an air hub 612, and a bracket retainer 603 asillustrated in FIGS. 15 and 16. The supporting plate 602 comprises acurved channel 607 (FIG. 16) through which the air inlet tube 608passes. The air inlet tube 608 passes through the curved channel 607 andis held in position so as not to slide along the curvature of thechannel 607 by brackets 605. Brackets 605 have a round opening to fitthe air inlet tube 608. To adjust the position of the air inlet tube 608along the curvature of the curved channel 607 (FIG. 16), the brackets605 have two curved openings 609 to accommodate fasteners (not shown),such as a screw, which is used to connect the brackets 605 to eitherside of the support plate 602 (FIGS. 15 and 16) in various positionssuch that the air inlet tube 608 can be in various positions guidedalong by the curvature of the curved channel 607. Support plate 602 hasthreaded holes 610 through which screws can be used to fasten thebrackets 605 and the bracket retainer 603 to the support plate, andaccordingly, position the air inlet tube 608. The curvature of thecurved channel 607 shares the same radius of curvature as the main airchannels positioned around the mold cylinder 300, such that main airchannels will be able to come into contact with the air inlet tube 608when the air inlet tube 608 is positioned anywhere along the curvedchannel 607. This allows an adjustment of the position along therotation where air enters the main air channels 320 from, for example,the six o'clock position to the eight o'clock position. Accordingly, theposition along the path of rotation where molded products are ejectedcan be varied.

On the mold side of support plate 602, bracket 605 is situated betweenthe support plate and the bracket retainer 603, which is a shaped ringcorresponding to the perimeter of the brackets 605. The end of the airinlet tube 608 which presses against the mold cylinder 300 as it rotatescomprises of a plastic lip 613 pushed against the rotating mold cylinderby the use of a coiled spring (not shown) coiled around the air inlettube 608, and situated between the bracket 605 and the plastic lip 613.

The recessed panels 310, illustrated in FIG. 7, are on the outer surfaceof the mold cylinder 300. The number, shape, and size of the recessedpanels can vary depending on the desired shape of the final foodproduct. The panels 310 are recessed a depth “d” 340, as illustrated inFIG. 7, which corresponds to the thickness of porous inserts 335disposed in the recessed panels, illustrated in FIG. 11. In theembodiment illustrated in FIG. 7, the recessed panels contain furtherrecessed panels 311. In the embodiment shown, three further recessedpanels 311 are arranged in a longitudinal row along the outercircumference of the mold cylinder 300, each corresponding to theposition of mold cavities arranged in longitudinal rows. The furtherrecessed panels 311 contain raised supports 312 which are illustrated inFIG. 7 as rectangular.

The smaller channels 330 in FIGS. 8 and 9 supply air to the furtherrecessed panels 311 illustrated in FIG. 10 at the base 315 of thefurther recessed panel 311 from which raised supports 312 protrude. Thesmaller air channels 330 terminate at air channel outlets 331 on thebase 315 of the further recessed panels 311. The raised supports risefrom the base 315 of the further recessed panel a height “r” 314 whichcorresponds to the depth of the further recessed panel.

In other embodiments, the raised support 312 can be of a differentshape, and of a height less than the depth “r” of the further recessedpanel 311 to generate a desired fluid circulation or flow pattern behindthe porous inserts 335. While not being bound by any particular theory,it is believed that the further recessed panel 311 allows for fluid togather after being carried into the recessed area from the channels, andprovides for a more uniform delivery of fluid to the porous insert 335.

Porous inserts 335 are disposed in the recessed panels as illustrated inFIG. 11. The porous inserts 335 are pervious to fluids such as gas orliquid, or both. The porous inserts 335 can be made from non-ferrous orferrous sintered metal, such as stainless steel, synthetic materials,such as tetraflurorethylene, ceramics, or a combination or compositethereof. Other suitable materials can also be used to manufacture theporous insert. Suitable porous materials are further discussed in U.S.Pat. Nos. 3,427,649, 4,212,609, and U.S. Patent Application2005/0220932, which are herein incorporated by reference. The porosityof the inserts allow fluid, usually air, that is delivered from theunderside of the inserts via the smaller channels 330, to reach the moldcavity 420 and assist in ejecting the molded food product from the moldcavities 420, as illustrated in FIG. 9.

Pore sizes should be of sufficient size to allow for the desireddelivery of fluid to the mold cavities, and small enough to be able toprovide enough support and withstand mold pressure at the bottom of themold cavity. Pore sizes can range, for example, in one embodiment, from0.5 to 100 micrometers. Different types of porous structures andinterconnection of porous passage ways are also possible to providedesired fluid flow through the porous inserts, as well as to preventmold product from being deeply embedded in the porous bottom wall.Various pore shapes and structures, such as, for example, irregularshapes and channels that interconnect at sharp angles, are less likelyto allow for mold product to be embedded.

The porous inserts 335 are designed so that they can be easily removedfor cleaning, or replaced by other porous inserts with differentcharacteristics to suit the type of food product being molding. Havingremovable and replaceable porous inserts allows for more efficientcleaning, repair and maintenance, as well as providing a moldingapparatus that is highly versatile.

Mold Shell

The cylindrical mold shell 400, illustrated in FIG. 12 comprises moldshapes 410 arranged in longitudinal rows along the length of thecylindrical shell. In other embodiments, each row may have the same or adifferent number of mold shapes which form a mold cavity when a bottomsurface is present, or the cavities on the mold shell may be staggeredto allow the pump to move product constantly and/or to maintain constantpressure while filling the mold cavities.

The cylindrical mold shell 400 is disposed around the mold cylinder 300such that the mold shapes 410 are situated over the porous inserts 335in the recessed panels. The mold shapes 410 provide configured sidewalls to the mold cavity 420. FIG. 6 illustrates the configuration ofthe rotary cylinder 299, with the mold cavity 420 being formed by themold shape 410 and the porous insert 335 as the bottom of the moldcavity. The mold cavity 420 is formed by the mold shape 410, wherein thethickness of the mold shell corresponds to the depth of the side wallsof the mold cavity 420. The mold cavity 420 opens radially.

A mold cavity 430 with the insert which functions as the porous bottomwall of the mold cavity is removed in FIG. 6, to clarify theconfiguration of the mold cavities, wherein each of the mold shapes 410is situated over a further recessed panel 311. In other embodiments,porous inserts can be disposed over recessed panels without a furtherrecessed panel below.

The mold shell can be easily removed for cleaning and/or repairs, aswell as easily replaced by mold shells with other shapes to suit thefood product shape desired. Because the mold shell and the porousinserts, which are all removable, are the only portions of the rotarycylinder that come in contact with food product, the rotary moldingapparatus allows for a versatility and efficiency not seen in prior artmolding devices.

The mold shell 400 is held in place over the mold cylinder 300 with basemembers 440, illustrated in FIGS. 1 and 13, on either end of the rotarycylinder 299 to prevent the mold shell 400 from sliding off the moldcylinder 300, as illustrated in FIG. 13. The cylindrical mold shell 400in FIGS. 12 and 13, has top and bottom edges 460 which are keyed so asto interlock with the flanges 451 on the base members 440 when thecylindrical mold shell 400 and the base members 440 are engaged. Thebase members 440 comprise a central opening 450 for a shaft 453 whichprovides the axis of rotation. The base member 440 comprises air channelholes 452 which allow for an external source of fluid to reach the mainair channels 320.

Fluid flow through the porous bottom wall assists in the ejection of themolded food product from the mold cavity. In one embodiment, where airis forced through the porous bottom walls to eject the mold product fromthe mold cavities, the air flow through the main air channels iscontrolled such that only the main air channels supplying the fluid tothe row of molds ready for ejection receives air flow sufficient toeject the mold. This can be achieved, for example by having an externalfluid source situated at a location where the main air channelcorresponding to a particular row of molds ready to be ejected comesinto contact with the external fluid source once it reaches a set pointon the rotation. For example, an air supply source can be provided atthe six o'clock position, where the mold cavities that rotate along ahorizontal axis open downwards so as to allow gravity to assist in theejection. An air source can be situated at the six'o clock position tocontinuously provide a stream of pressurized air such that any mainchannel rotating past the position will receive a stream of air flow soas to allow fluid to pass through the porous bottom walls and eject themolded product.

In one embodiment, the fluid flow through the porous bottom wall can becontinuous, so that fluid is passing though the porous walls even duringthe filling process. The fluid is forced through the porous walls at apressure less than the filling pressure of the food product being fedinto the mold cavity to ensure that the mold cavity can be filled. Asthe rotary molding apparatus provides for an air discharge outlet, thefluid, usually air, is not entrapped in the mold cavity. The pressurefrom the fluid can also assist in exerting additional pressure on thefood product in the mold cavity when the mold is in its closed position.

In another embodiment, illustrated in FIG. 29, a mold shell 900 allowsmold cavities 910 to be rotated from a fill position at approximately anine o'clock position to an eject position at approximately a sixo'clock position. At the eject position, the food product 911 within themold cavity 910 is ejected using a stream of fluid such as air. Air in amain air channel 912 flows into a series of smaller channels 914 whichare in communication with an air pressure region 915. Air pressureregion 915 allows air exiting the smaller channels 914 to exert pressuremore evenly on the food product 911 to eject the food product. The flowof air into the air pressure region 915 is regulated using an air port913. When the main air channel is oriented such that the air port 913 isin communication with the smaller channels 914, pressurized air flowsinto the air pressure region 915 to eject the food product. To restrictthe flow of air from the main air channel 912, the main air channel isrotated in a direction “C” as indicated by the arrow such that the airport 913 is not aligned in communication with the smaller channels 914.The air pressure region 915 spans a distance wider than the width of themold cavity 910, such that the entire mold cavity 910 may be in contactwith the air pressure region 915. Once the food product 911 has beenrotated to a desirable ejection position, for example where the foodproduct is at its lowest position, as illustrated in FIG. 29, such thatair pressure exerted on the food product will be exerted downwards, theair port 913 is aligned such that the air channel 912 is incommunication with the smaller channels 914 which allow a flow of air toeject the food product. The air port 913 may remain out of communicationwith the smaller channels 914 until the leading edge of the mold cavityhas rotated to just before the front region 916 of the air pressureregion 915. The duration of air flow is adjusted depending on the moldshape and size, and may be optimized by one skilled in the art. Byhaving an air pressure region 915, various shapes of molded food productmaybe ejected from the mold so long as the shaped cavities are withinthe area defined by the air pressure region 915.

FIG. 29A illustrates one method of implementing the pressurized fluidejection system of FIG. 29. An air source channel 912 a supplies air tothe main air channel 912. Multiple air source channels can also be used.The intersection of the air source channel 912 a and the main airchannel 912 is a sealed rotary connection 912 b (shown schematically)such that the main air channel 912 can rotate at the intersection 912 band receive pressurized air from the channel 912 a for periodic ejectionof air through the air port 913. The rotations of the main air channel912 can be actuated by a series of gears. Gear 918 a is driven by a geartrain 918, schematically illustrated, which is rotated by a common shaft919 a driven by a motor 919. The rotation of the main air channel 912connects and disconnects the source of air into the air pressure region915. The air pressure region 915 is a rectangular shaped chamberconnected at the top surface 915 a to the smaller channels 914. Thebottom perimeter 917 of the air pressure region 915 preferably forms aseal against the rotating mold. As illustrated in FIG. 29A, the airpressure region is disposed over the mold cavities 910, and is capableof ejecting irregular shaped food patties formed by mold cavities 910which fit within the bottom perimeter 917 of the air pressure region915.

Air pressure region 915 and connected smaller channels 914, as well asmain air channel 912 and air source channel 912 a, may be supported inplace by securement to a stationary surface or support structure withinthe rotary mold. Such a stationary surface or support structure may be amandrel 776 as illustrated in FIG. 19A.

In another embodiment, the rotary cylinder 299 is operated by a motor500, as illustrated in FIG. 14, which is attached to a motor adaptorplate 501. The motor adaptor plate 501 is attached to a supporting plate502 by gear spacers 503. The motor 500 drives the drive gear 520 whichis situated between the motor adaptor plate 501 and the supporting plate502. The drive gear 520 is adjacent to, and drives the driven gear 510.The driven gear 510 is attached to a shaft 550 with an axis around whichthe rotary cylinder 299 rotates. The cylindrical mold shell 400 and themold cylinder 300 (FIG. 1) rotate together as a result of thecylindrical mold shell 400 and the mold cylinder's 300 engagement withthe base members 440. The cylindrical mold shell 400 has edges 460(FIGS. 12 and 13) that are keyed so as to interlock with the flanges 451on the base members 440 when the cylindrical mold shell 400 and the basemembers 440 are engaged. The base members engage the mold cylinderthrough the use of hollow dowels 540 which come in contact with the mainair channels 320 (FIG. 7). Housings 560, and various other componentssuch as washers, spacers, seals, pins and bearings 561A to 561Q, asshown in FIG. 17, that would be known to one skilled in the art,connects the shaft 550 to the base members 440, allowing the basemembers 440 to rotate in accordance with the driven gear 510.

FIGS. 18 to 21 illustrate an alternative embodiment of a rotary moldingsystem comprising a knock-out mechanism. The rotary molding systemcomprises a feeder portion 700, a fill plate 760, a wear plate 770, aknock-out mechanism 800, and a rotary mold 900 comprising mold cavities910. The feeder portion 700 provides a steady stream of food product tothe fill plate 760 for deposition into the mold cavities 910. The wearplate 770 acts as a bottom surface to the mold cavities 910 when themold cavities are rotated into position over the wear plate 770 whenbeing filled. When the filled mold cavities 910 are rotated to theireject position, the knock-out mechanism 800 operates to eject the moldedfood product from the mold cavities onto a moving surface positionedbelow the eject position.

Feeder Portion 700

FIG. 18 illustrates the feeder portion 700 of a rotary molding system ofanother embodiment of the present invention. The feeder portioncomprises a feeding channel 710 within a feed plate 703. The feed plate703 comprises a curved portion 705 which is adapted to complement thecurvature of the rotary mold 900.

The food product enters the feeding channel 710 at a feeding channelinlet 706 located generally in the central region of the feed plate 703as illustrated in FIG. 18. From the channel inlet 706, the food channel710 gradually fans out to a length “L,” corresponding approximately tothe distance spanned by a longitudinal row of mold cavities, to ensuredelivery of food product to all mold cavities within a longitudinal row(FIG. 23). The feeding channel 710 has a frustoconical cross section, asillustrated in FIGS. 18 to 20, which assists in gradually increasing thepressure of the food product as the food product moves toward the rotarymold for injection into mold cavities 910.

A feeding channel adaptor 704 is used to connect the feeding channel toa source of pumped food product. Food product is moved into the feedingchannel 710 from a food hopper 701 using a pump 702 as discussed abovewith respect to the previous embodiment of the invention.

The feeding channel 710 is connected to an outlet portion 715 at the endof the feeding channel 710 closest to the curved portion 705. The outletportion 715 is a channel with a rectangular cross section which spans alength “L” corresponding approximately to the distance spanned by a rowof mold cavities, as illustrated in FIG. 23. The outlet potion 715 is incommunication with the fill plate 760.

In another embodiment, illustrated in FIG. 30, the feeder portion 700 acomprises two feeding channels 710 a within feed plate 703 a. Theproduct enters the feeding channels 710 a via feeding channel inlets 706a, which are generally evenly spaced within the feed plate 703 a. Likethe feeding channel 710 described above, each feeding channel 710 agradually fans out, and is in communication with each other at theoutlet portion 715 a of the feeding channel 710 a. The outlet portion715 a spans a length corresponding approximately to the distance spannedby a row of mold cavities. In other embodiments, more than two feedingchannels can be used in a similar fashion to encourage food product tospread evenly through the feeder portion and to minimize the distancefood product travels from the channel inlets 706 a.

Fill Plate 760

The fill plate 760, as illustrated in FIG. 26, is a curved platedisposed in contact with the curved portion 705 of the feed plate 703(FIGS. 18-20). The fill plate 760 is disposed between the rotary mold900 and the curved portion 705 of the feed plate 703. The fill plate 760comprises a feeder inlet passage 720 through which the food productpasses to enter the mold cavities 910. The feeder inlet passage 720 maycontinuously span a length “L”, corresponding approximately to thedistance spanned by a row of mold cavities, as illustrated in FIG. 23,or alternatively, be distinct openings in the fill plate 760 which arenot connected continuously.

As illustrated in FIG. 26, the feeder inlet passage 720 is asymmetricalalong its longitudinal axis “b,” and symmetrical on either side of axis“c.” The feeder inlet passage 720 has a narrower central portion 768,which gradually expands with increasing distance from central axis “c.”Feeder inlet passage 720 is narrower in the central portion to allow formore uniform filling of each mold cavity within a row, regardless oftheir proximity to the feeding channel inlet 706. Without beingregulated by the feeder inlet passage 720, the mold cavities 910 in thecenter of the rotary mold which are closest to the feeding channel inletwould be filled with food product at a higher pressure and/or a greaterflow rate as a result of its proximity to feeding channel inlet 706,than mold cavities 910 situated near the end of the rotary mold 900.

Other mechanisms for evenly distributing the filling pressure at theinlet passage 720 can be used. For example, distinct openings which maybe uniform in size, or which increase in size, as the distance from thecentral region 768 increases can also be used to evenly fill the moldcavities.

The fill plate 760 comprises breather regions 765 which are perforatedwith air channels (not shown) whose outlets 766 are shown in FIG. 26.The breather region 765 comprises elongated recessed grooves 767 whichdo not penetrate the entire thickness of the fill plate 760. Thechannels are of a depth spanning the remaining thickness of the fillplate 760 in the grooves 767, and is in communication with the surfaceof the rotary mold 900, or a mold cavity 910, as the rotary mold rotatespast the breather regions 765. The breather regions span a length “L”,corresponding approximately to the distance spanned by a row of moldcavities, as illustrated in FIG. 23. The breather regions allow for airdisplaced by the incoming food product in the mold cavity 910 to exitthe mold cavity as it is increasingly filled with food product. Thebreather regions 765 and feeder inlet passage 720 are situated at adistance such that portions of the mold cavity can be in contact withthe feeder inlet passage 720, and the breather regions simultaneously.In operation, the rotating mold rotates in a direction such that themold cavities first come in contact with the breather regions, and thenwith the feeder inlet passage 720. As the mold cavity 910 rotates pastthe feeder inlet passage 720, food product simultaneously fills the moldcavity and displaces the air remaining in the mold cavity. Because aportion of the mold cavity 910 is still in contact with the breatherregions 765 as the mold is being filled with food product, the displacedair leaves the mold cavity 910 via the air channels in the breatherregion 765.

The air channels are preferably of a suitable size to allow fordisplaced air to exit the mold cavity 910, while preventing food productfrom entering the air channels. However, it is often the case that smallportions of food product are squeezed into the air channels. Displacedair from each of the breather regions 765 is collected in a displacedair chamber 768 disposed in contact with the breather regions 765 (FIG.19). The air in the displaced air chamber 768 is connected to an airdischarge channel 769 which can transfer the discharged air, along withany food products, back towards the food hopper 701. The fill plate 760may comprise a scraper or wiper 762 to channel food products which endup in the clearances, towards the hopper. Food products captured by thescraper or wiper 762 are in connection with air channels which transportthe food products back towards the hopper 701.

The fill plate 760 further comprises an overflow groove 721 disposedaround the perimeter of the feeder inlet passage 720 as illustrated inFIGS. 26 and 19. The overflow groove 721 is a recessed groove in thefill plate disposed around the feeder inlet passage 720. The overflowgroove 721 captures food product, which when exiting the outlet portion715 at high pressure, may be forced between the feed plate 703 and thefill plate 760. The overflow groove 721 can be of other suitable shapes,such as a rectangle, around the feeder inlet passage 720.

Because the fill plate 760 is in contact with a continuously rotatingrotary mold 900, the fill plate 760 comprises sealing mechanism or layer707 disposed on the rotary mold side of the fill plate to ensureadequate close contact with the rotary mold and prevent food productfrom leaking from the mold cavities 910 once the mold cavities 910 arefilled (FIG. 18).

The fill plate is in contact with a portion of the rotary mold 900defined by the intersection of an angle “a” with the rotary mold 900, asillustrated in FIG. 19, and extends for a length L,” which correspondsapproximately to the distance spanned by a row of mold cavities, asillustrated in FIG. 23, or just slightly greater than length “L.” Thefill plate can extend a length “d” as illustrated in FIG. 21, whichextends beyond the length of the rotary mold, extend a length “r”corresponding to the length of the rotary mold, or a length “f” whereinthe fill plate extends beyond the rotary mold on one end, or any othersuitable length.

In another embodiment, the fill plate 760 a (FIG. 31) comprises a vacuumregion 765 a connected to a vacuum channel 766 a. The vacuum region 765a is situated upstream of the feeder inlet passage 720 a. In operation,the rotating mold rotates in a direction such that the mold cavitiesfirst come in contact with the vacuum region 765 a, and then the feederinlet passage 720 a wherein the mold cavities 910 are filled with foodproduct. In this embodiment, the vacuum region 765 a and the feederinlet passage 720 a are not spaced such that a portion of the moldcavity can be simultaneously in communication with both the vacuumregion 765 a and the feeder inlet passage 720 a. As the mold cavity 910rotates past the vacuum region 765 a, air trapped in the cavity thatwould otherwise take up space in the mold cavity and prevent the moldcavity from filling evenly, is removed.

In an alternate embodiment, the vacuum region 765 a and the feeder inletpassage 720 a may be situated such that a portion of the mold cavity 910is in contact with the vacuum region 765 a as the mold is being filledwith food product. The vacuum force assists in removing the displacedair.

A vacuum pump can be used to provide the source of vacuum for the vacuumregion 765 a, or alternatively, low pressure regions in the rotarymolding machinery may be used to provide a source of vacuum.

In yet another embodiment, a fill plate 1100 as illustrated in FIG. 32can be used with the rotary mold. The fill plate 1100 has a perforatedregion 1120 wherein food product is passed through to provide adifferent texture to the food product than achieved through using a fillplate 760 with a fill slot. The fill plate 1100 is curved in accordancewith the radius of curvature of the rotary mold on one side, andsubstantially flat on the opposite side such that it may be disposed incontact with the feed plate 1140. Disposed behind the fill plate 1100 isthe feed plate 1140 which channels food product toward the fill plate1100. The fill plate 1100 has a scraper or wiper 1130 to retrieve foodproducts which are on the surface of the rotary mold and not within themold cavities.

FIG. 33 illustrates an alternate perspective view of the feed plate 1140and fill plate 1100 of FIG. 32. Feeding channel inlets 1145 which allowfood product to enter the fill plate 1100 are on the side of the feedplate 1140 opposite from the fill plate. FIG. 34 is a perspective viewof FIG. 33, with the feed plate 1140 removed for clarity. A stripperplate 1150 is disposed between the fill plate 1100 and the feed plate1140 (FIGS. 32 and 33). A stripper plate 1150 is preferably used with aperforated fill plate 1100 as food product or food product fibers aremore prone to be caught within the perforations than within a fill slot.The stripper plate 1150 comprises a perforated region 1170. The holes orperforations of the stripper plate 1150 are preferably the same sizeopening as the perforations in the fill plate 1100. The stripper plate1150 slides across the side of the perforated region closest to the feedplate to sever any residual food product fibers which may be caught inthe perforations after each time the food product is passed through theperforated region. The operation of the stripper plate is discussed infurther detail in U.S. application Ser. No. 11/408,248, published asU.S. Patent Application Publication 2007/0098862.

As illustrated in FIG. 34, each side of stripper plate 1150 has two pushrods 1171 that abut the stripper plate. The rods 1171 have disk shapedheads 1172 that are in contact with the edge of the stripper plate. Theheads allow for an eccentric arrangement of the rods 1171 with regard tothe stripper plate 1150. Rods 1171 extend through the side wall 1141 ofthe feed plate 1140 (FIGS. 33 and 34) and are connected to a drivemechanism, preferably one or more hydraulic cylinders (not shown). Thisarrangement allows the stripper plate 1150 to slide back and forthacross the back of the fill plate 1100.

The feed plate 1140 is fastened to the fill plate 1100 via a pluralityof screws 1142 across the top and bottom of the feed plate 1140. Thefeed plate is also attached to support plates 1146 on either side of therotary mold via bolts 1147.

A standard fill plate 1100 a with one fill slot 1111 can also be usedwith the rotary mold by exchanging the perforated 1120 fill plate 1100with a standard fill plate 1100 a and its associated feed plate 1140 a(FIGS. 34A, 34B). The feed plate 1140 a is attached to the support platevia bolts 1147, and is attached to the fill plate 1100 a via a pluralityof screws 1142. The use of the standard fill plate 1100 a with one fillslot 1111 in this embodiment does not use a stripper plate, and thusdoes not require channels on the side walls 1141 a for accommodating thestripper plate rods. By having easily interchangeable parts for formingthe desired type of food patty, the versatility of the rotary moldingsystem is increased.

Rotary Mold 900

The rotary mold 900 comprises mold cavities 910 (FIGS. 18-21 and 23)disposed around the rotary mold. The rotary mold 900 is a cylindricalshell with the thickness of the shell corresponding to the depth of themold cavity 910. Mold cavities 910 are rotated from a fill position toan eject position. In the embodiment illustrated in FIGS. 18-20, themold cavity is filled with food product when it rotates counterclockwise to the 9 o'clock position where the outlet portion 715 of thefeeding channel is located, and food product is ejected, with theassistance of gravity, when the mold cavity rotates to the 6 o'clockposition.

The number of mold cavities around the circumference of the mold cavitycan vary. An eight row rotary mold comprising eight mold cavities spacedaround the circumference of the rotary mold in each row is illustratedin FIG. 18 while a six row rotary mold is illustrated in FIG. 20.

The rotary mold 900 can be operated by a motor 1000 as illustrated inFIGS. 24A and 24B. The rotary mold 900 has base members 940 and edges960 on either end of the rotary mold. The base members 940 have flanges951 which extend radially, such as show in FIG. 1. The edges 960 of therotary mold 900 are keyed such that the edges can interlock with theflanges 951 on the base members 940 when the rotary mold 900 and thebase members 940 are engaged. The motor 1000 is connected to a motorshaft 1010 which spans the entire length of the rotary mold asillustrated in FIG. 24, and is received on the distal end of the rotarymold 900 by an outboard bearing 952. The motor shaft 1010 is connectedto at least one of the base members 940 such that the rotation of theshaft 1010 rotates the base members 940 which in turn rotate the rotarymold 900 as a result of the engagement of the base member flanges 951and the keyed edges 960 of the rotary mold 900. One skilled in the artwould recognize that other embodiments where the shaft 1010 does notspan the entire length are possible.

When the rotary mold is operated by a motor 1000, the knock outmechanism 800 can be disposed and operated within the rotary mold asschematically illustrated in FIG. 28. The common shaft of the knock outmechanism 850 is disposed off center of the rotary mold 900 as a resultof its arrangement with respect to the motor shaft 1010. Because thetiming of the knock-out mechanism depends on the position of the moldcavities, and thus the rotation of the mold, appropriate timing for theknock-out mechanism is achieved by coupling the knockout mechanism 800with the rotation of the motor shaft 1010. Coupling the knockoutmechanism 800 with the movement of the motor shaft 1010 is achievedthrough the use of a plurality of gears. For example, a gear 1020disposed for rotation with the motor shaft 1010 is coupled to a geartrain 1030 which drives the knock out mechanism 800. Alternately, aseparate motor can drive the knock out mechanism.

In an alternative embodiment, the rotary mold is operated by toothedendless belts 1040 as illustrated in FIG. 27. The rotary mold comprisesa toothed gear ring 1060 about the circumference of the rotary mold 900at each end of the rotary mold. The toothed gear ring 1060 engages witha toothed endless belt 1040 which contains a toothed surface 1061 withwhich the toothed gear ring engages. Each belt 1040 is driven by rollers1070 which are connected via a common shaft 1080. A motor 1050 drivesthe rollers 1070. The belts are further supported by idle supportrollers 1071 connected via a common shaft 1081. The rollers 1070, 1071can optionally comprise a toothed ring. In an alternative embodiment,support rollers and their common shaft 1081 can be removed depending onthe desired configuration, such that the belt only wraps around one setof rollers 1070. FIGS. 34B and 34C illustrate the toothed endless belt1040 wrapped around one set of rollers 1070. The endless drive belt 1040system further comprises tensioners 1090 disposed against the belt 1040.The tensioners are held against the belt to allow the belt 1040 toengage more tightly to the toothed gear ring 1060 and the rollers 1070.In FIG. 34C, the tensioners 1090 are held in place against the belt 1040to provide the desired degree of tension by supports 1095 mounted to thefeed plate 1140.

Alternatively, the rollers 1070 and the tensioners 1090 can bepositioned further away from the feed plate 1140 as illustrated in FIG.34B. The tensioners 1090 can be held in place by supports 1090 a whichcan be mounted to a support frame 1090 b as illustrated in FIG. 34D, orany other mechanism. The tensioners 1090 can be placed anywhere alongthe belt 1040 to encourage a tighter engagement of the belt 1040 and itsdriving components.

The supports 1095 can be one time adjusted and set to exert the desiredbelt tension or can include springs or pressure actuators to exert aresilient force of the tensioners against the belt 1040.

Wear Plate 770

As illustrated in FIG. 19, the rotary mold system comprises a wear plate770 with an outer surface 775 disposed in contact with the inner surface920 of the rotary mold 900. As the rotary mold 900 rotates into the fillposition, the rotary mold 900 becomes disposed between the fill plate760 and the wear plate 770, with the outer surface 775 of the wear plate770 serving as the bottom surface to the mold cavities 910 as the moldcavity rotates through the region where it is in contact with the fillplate and the wear plate. The wear plate 770 remains stationary as therotary mold rotates past the wear plate 770.

A D-shaped cross sectional backing plate 780 behind the wear plate 770provides support for the wear plate as pressure from filling the moldcavities is exerted into the mold cavities during the filling process.The backing plate 780 further allows bolts 790 to be screwed into a flatsurface.

The wear plate 770, including the D-shaped backing plate 780, extendscontinuously for a length “d” as illustrated in FIG. 21. The wear plate770 is in contact with a portion of the inner surface of the rotary molddefined by an angle “a” (FIG. 19). The wear plate is held in place usingbolts 790 which are used to secure the wear plate 770 and the backingplate 780 to the feed plate 703. The bolts 790 are located on either endof the molding apparatus, extending beyond the rotary mold 990 so thebolts do not interfere with the rotation of the mold.

The bolts 790, in securing the wear plate 770 to the feed plate 703,also secures a spacer 771 with a thickness slightly greater than thethickness of the rotary mold to allow clearance for the rotation of themold, and a spacer 772 for the fill plate if the fill plate does notextend to a length so it can be held by bolts 790, such as, for example,when the fill plate is a length “L” corresponding to the length the rowof mold cavities span.

A mechanism for holding spacer components 771 and 772 in place duringcleaning or maintenance of the rotary mold is used to prevent thespacers from disassembling when the bolts are removed. Fasteningmechanisms such as screws can be used to join the spacer componentstogether to prevent disassembly. Alternatively, a cradling mechanism canbe used to ensure that the spacer components stay in position.

The rotary mold can be pivoted away from the feed plate 703 asillustrated in FIGS. 23, 24A, and 24B for cleaning, maintenance, orrepairs. A pivoting mechanism 1110 or 1100 provides a hinge about whichthe rotary drum can pivot.

In an alternate embodiment, instead of using a wear plate 770 to providesupport for the rotary molding apparatus, a mandrel structure 776 asillustrated in FIG. 19A can be used to provide structural support to therotary molding apparatus. The mandrel structure 776 extends for thelength of the rotary mold, and comprises two winged regions 776 a, 776 bwhich come in contact with the inner surface 920 of the rotary mold toprovide support to the rotary mold as it rotates. The mandrel structure776 can be cantilevered from one end of the rotary mold. Alternatively,the mandrel structure 776 can extend beyond the rotary mold to besupported on either end by a support structure (not shown) as known toone skilled in the art.

Knock-Out Mechanism 800

FIGS. 18 to 21 illustrate the knock out mechanism 800, which is disposedin the inner region 940 of the rotary mold 900 (FIG. 20). The knock-outmechanism, illustrated in FIG. 20, comprises stabilizing plates 810,movement plates 820, driving gears 830, and driven gears 840.

Two stabilizing plates 810 are rigidly attached to the wear plate 770,as illustrated in FIG. 20. A driving gear 830 is associated with eachstabilizing plate 810, the driving gears 830 being rotationally mountedto the stabilizing plates by a rotating, common shaft 850 beingjournalled through the plate. The shaft 850 is attached to a motor 851(FIGS. 20 and 21). A set of two driven gears, a top driven gear 840 aand a bottom driven gear 840 b, are disposed in association with eachdriving gear 830, such that a clockwise rotation of the driving gear 830in direction “A” results in a simultaneous rotation of driven gears 840in counterclockwise direction “B” as illustrated in FIG. 20. Each drivengear 840 a, 840 b is attached to a corresponding spaced apart drivengear 840 a, 840 b on the other stabilizing plate 810 by a rotatingcommon gear shaft 860 a, 860 b across and through the stabilizing plate810. The rotating, common gear shafts 860 a, 860 b, hold the driven gearpairs 840 a, 840 a; 840 b, 840 b in position, and stabilize the rotationof the driven gears 840 a, 840 a; 840 b, 840 b.

Each movement plate 820 is connected to a driven gear pair 840 a, 840 a;840 b, 840 b by a pair of eccentrically mounted pins 871 a, 871 b. Theeccentrically mounted pins 871 a, 871 b connect the movement plates 820to the driven gears at a position that is off-center of the axis of thedriven gears 840 a, 840 a; 840 b, 840 b, such that the location of theoff-center connection allows for control over the range of movementimparted to the movement plate. The range of movement imparted to themovement plate corresponds to the desired range of movement required byknock-out cups to eject molded food products from the mold cavitieswhile the rotary mold is in continuous rotational movement.

The movement plates 820 are attached to a movement bar 880. The movementbar 880 is a horizontal bar oriented parallel to the longitudinal axisof the rotary mold which allows the movement of the movement plates 820to be transferred to knock out cups 885 attached to the movement bar880. The movement bar is connected to knock out cups, corresponding innumber to the number of cavities along a longitudinal row of the rotarymold. The movement bar 880 transfers the movement of the movement plate820 to the knock out cups 885, allowing each knock out cup to travel ina trajectory that can knock out food product from a rotating moldcavity.

The movement bar 880 is connected to the knock out cups 885 via an innermovement bar 882 which is nested within the length of the movement bar880 (FIG. 25). The movement bar 880 comprises a grooved recess 881,which is complementarily shaped to receive the inner movement bar 882.The inner movement bar 882 is connected to each of the knock out cups885 via a connecting mechanism 890 as illustrated in FIGS. 21 and 25.

The connecting mechanism 890 illustrated in FIG. 25 comprises two screws889 which are used to connect the knock out cups 885 to the innermovement bar 882. The knock out cup comprises two shafts 886 extendingfrom the top surface of the knock out cups, each shaft comprising a bore887. The bores 887 in the knock out cup shafts 886 are in alignment withbores 888 in the inner movement bar 882 such that bolts 889 can beinserted through the bores 887,888 to fasten the knock-out cups 885 tothe inner movement bar 882 by a threaded mechanism, for example.

The movement plate 820 transfers its movement to the knock out cups 885to provide a downward range of motion starting from resting position D,as illustrated in FIG. 25, to an intermediate position E, to a knock-outposition F. FIG. 22 illustrates the position of the knock-out cups 885as a function of the position of the non-rotating shaft 871 relative tothe center of the driven gear 840. FIG. 20 illustrates the gears and theknockout cups in their resting, elevated position. The trajectory of theknock out cups as dictated by the off-center connection of the movementplate to the driven gears permits the knock out cups to move in a mannerwhich allows for knocking out molded food products in a continuouslyrotating rotary mold. The position of the knock out cups correspondingto the different rotational positions a, b, c, d, e, g, h, i, j, k ofthe driven gears are illustrated in FIG. 22. The knock-out mechanism isable to operate with mold cavities of various shapes, includingasymmetrical or irregularly shaped cavities.

Heating System

When a knock out cup continuously ejects food patties, such as red meatfood patties, fat accumulation may hamper the efficiency of the knockout process. To prevent fat accumulation on the edge of the knock outcups, a heating system can be used in conjunction with the knock outmechanism. In one embodiment, the heat source is provided by channelingheated air into the region around the knock out cups to form a heatedair curtain around the knock out cups. The use of hot pressurized airallows for efficient control of the temperature of the knock out cups,and minimizes the wait time for the region around the knock out cups toreach a desired temperature or for the temperature to decrease once theheating of the knock out cups is no longer desired. Efficient control ofthe temperature is achieved because the air can be turned on and off atthe source.

In one embodiment, as illustrated in FIG. 53, a heating systemcomprising a heat source 4000 is disposed on either side of the knockout cup.

In the embodiment illustrated in FIG. 55, air or gas is introduced intoan inlet 4013 of an air heater 4014 which heats the air to a desiredtemperature when the air passes through the air heater 4014. The airheater 4014 can be one similar to the super high watt density cartridgeheaters sold by Hotwatt, Inc., Danvers, Mass., or any other suitableheater known to one skilled in the art. Once heated, the air flows fromthe air heater 4014 into an outlet 4015 which channels the air into anair duct 4016. As the air exits from the air heater 4014 into the outlet4015, the air flows through a temperature probe port 4017 whereintemperature of the exiting air can be monitored. The air duct 4016splits the air flow into two branches, 4018 a, 4018 b. Each air ductfeeds the air past an internal air manifold 4019 in communication withair ports 4020 a, 4020 b drilled through portions of the support frameof the rotary mold. The air in each branch then converges at an externalair manifold 4021 (FIG. 56). At the external air manifold 4021, theheated air is branched to flow to an air tube 4010 disposed on eitherside of the knock out cups 4013. In other embodiments, a plurality ofair tubes can be used on either side of the knock out cups.

As illustrated in FIG. 56, the perforated tube may be an air tube withholes 4012, slots 4011, or any other opening, which allows hot airpassing through the tube 4010 to exit at and around the knock out cups4013 (shown in dashed lines). Tubes can be any shape suitable forproviding the desired flow of heated air surrounding the knock out cups.The air tubes 4010 are supported on one end by a support block 4030connected to a support frame 4040 of the rotary mold. The support blocks4030 are connected to the support frame 4040 using bolts 4031. On theopposite end of the support blocks 4030, the air tubes 4010 are fittedwithin a receiving member 4022 connected to the external air manifold4021. The receiving member 4022 positions the air tube 4010 incommunication with the external air manifold.

As illustrated in FIG. 53, the air tubes 4010 are arranged above knockout cups and provide heated air flow in a downwards direction towardsthe knock out cups. Air flow exiting the air tube can span an angle of25 degrees around the perimeter of the air tube. The air tube isdisposed such that hot air flow reaches the corners and/or edges of theknock out cups.

Air can be introduced into the heating system through an external sourcesuch as a supply of air from an air tank, or a compressor. Alternativelyair can be introduced from a supply of air generated by, or the samesupply of air used for other parts of the apparatus. The heating systemcan be used with any molding system that includes knock out cups.

Verification System

In one embodiment, the food patty molding apparatus comprises averification system for ensuring that the rotary mold is used with acorresponding set of knock out bars. In one embodiment, an RFID chip isdisposed on the knock out cup bar 4051 as illustrated in FIG. 54. AnRFID sensor for the knock out cup bar RFID chip is disposed in proximityto the end of the knock out cup bar containing the RFID chip. The sensorcable (not shown) can be routed though the support frame of the rotarymold via a sensor cable passage tube 4053. A second RFID chip (notshown) can be disposed on the rotary mold cylinder, such as on thesurface of the rotary mold cylinder, or any other suitable location. ARFID sensor for the rotary mold is placed accordingly in a position toallow reading of the RFID sensor on the rotary mold.

The sensors communicate information on the knock out bar installed andon the rotary mold cylinder installed to a central processing unit, suchas to the central machine control. If the central processing unitdetermines that the two components are compatible, the user will be ableto proceed with operation of the rotary mold. If the central processingunit determines that the two components are not compatible, the user isnotified. Once a compatible knock out bar and rotary mold cylinder pairis installed, the user is allowed to begin operation of the moldingsystem. Any other type of smart tagging system, or a system for ensuringcompatibility of the rotary mold cylinder and the knock out cups priorto operation can also be used. The use of an RFID verification systemprevents accidental user mismatch of knock out cups with the rotary moldshell, or with a reciprocating mold plate. Information such as the shapeand dimension of the knock out cups, as well as which rotary mold ormold plate the knock out cups are compatible with, can be stored on theRFID chip. Similarly, an RFID chip on the mold shell or mold plate willcontain information on the dimensions of the mold cavity and the moldshell or mold plate's compatibility with knock out cups.

Alternate Knock-out Mechanisms

In another embodiment, as illustrated in FIG. 35, the knock-outmechanism 1200 comprises a coupling 1230, a piston 1240, and an airpressure region 1210. The piston is disposed within an air pressureregion 1210 to generate air pressure within the air pressure region. Arapid downward force as the piston moves from its retracted position “a”to its extended position “b” creates a pressure wave or “burst” ofpressure within the air pressure region 1210 which is used to expel themolded food product from its mold cavity.

The air pressure region 1210 as illustrated in FIGS. 35 and 35B is arectangular cylindrical shaft defined by walls 1220 and 1222 whichprovide a rectangular perimeter as illustrated in FIG. 35B. The piston1240 is shaped accordingly to fit within the air pressure region 1210and to allow the piston 1240 to move up and down within the air pressureregion. The bottom surface 1241 of the piston 1240 is curved inaccordance with the radius of curvature of the rotary mold, so that thepiston 1240 can extend up to the rotary mold surface. In otherembodiments, the bottom surface 1241 of the piston need not be curved,or extend up until the bottom surface is adjacent to the rotary moldsurface. Shafts of other shapes, such as a cylindrical or ellipticalshaft, may be used to form the air pressure region.

As illustrated in FIG. 35B, the mold cavities are of different shapes.However, because all the mold cavities are within the perimeter of theair pressure region 1210 as defined by walls 1220 and 1222, molded foodproducts of varying shapes can be ejected simultaneously by the buildupof pressure in the air pressure region which is exerted onto the moldedfood products.

The number of pistons 1240 and their associated air pressure regions1210 correspond to the number of mold cavities in a row. FIG. 35Billustrates thirteen mold cavities in a row along the length of therotary mold. Accordingly, thirteen pistons and their associated airpressure regions are required to simultaneously knock out the moldedfood products. In an alternate embodiment, one air pressure region canspan more than one mold cavity.

To ensure that all the molded food products are knocked outsimultaneously, the pistons 1240 are moved in unison within the airpressure region. In one embodiment, as illustrated in FIGS. 35 and 35D,the pistons 1240 are connected to a movement bar 1880. Pistons areconnected to the movement bar via an inner movement bar 1882 which isnested within the length of the movement bar 1880. The movement bar 1880comprises a grooved recess 1881, which is complimentarily shaped toreceive the inner movement bar 1882. The pistons 1240 are connected tothe inner movement bar 1882 via a bolt 1889 which passes through theinner movement bar to secure itself within a threaded bore in the pistonstem 1890.

A coupling mechanism 1230 moves the piston rods 1250 in an upwards anddownwards direction which is transferred to the movement bar 1880, andaccordingly to the pistons 1240. In the embodiment shown in FIG. 35D,two coupling mechanisms 1230 are used for each of the piston rods 1250.The coupling mechanism 1230 comprises a disk 1260, a slider link 1280, apin 1290, and a common shaft 1270.

Disks 1260 are connected to the common shaft which causes the disk 1260to rotate as the shaft rotates. The pin 1290 is eccentrically mountedonto the disk 1260. The pathway of the pin 1290 as the disk 1260 rotatesis illustrated in dashed lines in FIG. 35A. The disks 1260 may be gears.In an alternate embodiment, disk 1260 on which the pin 1290 iseccentrically mounted may be driven by other gears, and not directlydriven by the rotating common shaft.

Pin 1290 engages with the slider link 1280 to convert the rotationalmovement of the pin 1290 into a linear movement which allows the pistonrod 1250 to move up and down. The slider link 1280 comprises a kinkedregion 1285. The position of the slinder link 1280 as the pin 1290rotates and translates motion via the slider link 1280 is illustrated inFIG. 35A. Preferably, the movement of the piston yields a rapid downwardforce to create a burst of pressure, and a more gradual upward force tocreate a gradual suction. The kinked region 1285 allows the upwardmotion to occur more gradually than the downward motion.

The common shaft 1270 is driven by a drive mechanism 1300 illustratedschematically in FIG. 35D. The drive mechanism 1300 may be a gear traindriven by the mechanism used to rotate the rotary mold, or the drivemechanism 1300 may be a motor. Other suitable drive mechanisms 1300 maybe used.

FIG. 35D illustrates the row of pistons 1240 which are disposed over themold cavities when the mold cavities are in their eject position. Airpressure regions 1210 are not shown for the remaining pistons forclarity. As illustrated, mold cavities of varying shapes can be usedwithin the same rotary mold because the air pressure region 1210 is notshape specific so long as the mold cavity fits within the rectangulararea defined by the air pressure region 1210. The air pressure region1210 is defined by side walls 1220 and 1222 which have a sealingmechanism where the side walls 1220 and 1222 contact the rotary mold.Each air pressure region can be held in place by being connected to acommon horizontal member 1215 which is connected to a member (not shown)that exerts a downward force sufficient to maintain a seal against therotating mold, while still allowing the mold to rotate. The horizontalmember 1215 may connect the air pressure region 1210 along the sidewalls 1220 as shown, or in between each air pressure region 1210 viaconnecting side walls 1222. In another embodiment, the air pressureregions 1210 are held in position against the inner surface of therotary mold by being connected to a mandrel 776 (FIG. 19A). Theconnection from the mandrel to air pressure regions 1210 createssufficient force to form a seal between the air pressure region and theinner surface of the rotating mold to minimize any air loss. Othermethods of securely positioning the air pressure regions 1210 againstthe rotating drum and over each individual mold cavity known to oneskilled in the art can also be used.

FIG. 35C illustrates an alternate embodiment of the coupling mechanism1400. The coupling mechanism 1400 comprises a D-shaped cam groove 1410on the surface of a rotating disk 1420. The rotating disk can be drivenby a common shaft 1430 in a similar fashion as described with respect toFIGS. 35 and 35D. Movement pin 1440 is disposed within the cam groove1410. Movement pin 1440 is connected to the piston rod (not shown inFIG. 35C) such that movement of the pin 1440 within the cam grooveactuates the up and down movement of the pistons to generate a downwardburst of pressure and a gradual suction as the piston retracts withinthe air pressure region. Groove path portion “a” corresponds to a riseor retraction of the piston head. Groove path portion “b” maintains thepiston head at a constant height during a dwell period. Groove pathportion “c” corresponds to the downward movement of the piston togenerate pressure.

FIG. 35E illustrates an alternate embodiment for a system of removingthe molded food products 1450 from the mold cavity 1451. As illustrated,the rotary mold comprises a plurality of mold cavities 1451 around theperimeter of the rotary mold.

The system comprises a conveying surface 1460 disposed over a vacuumregion 1470. The conveying surface 1460 is supported on a support frame1462, illustrated schematically in FIGS. 35E and 35F. The vacuum regioncomprises a vacuum chamber 1480 connected to a vacuum source (notshown). The vacuum chamber has a top surface that is a gas permeablelayer 1490. The gas permeable layer 1490 allows passing of air fortransferring the vacuum force.

The idle roller 1465 is of a size and at a location relative to therotary mold 1452 to contact the rotary mold 1452 at a point 1466 so asto allow the conveying surface 1460, in conjunction with a portion 1475of the gas permeable layer 1490, to form a radius of curvature whichconforms to the radius of curvature of the rotary mold. In an alternateembodiment, the support frame 1462 can be used to provide support forthe portion 1463 of the conveying surface between the idle roller 1465and the vacuum region 1470 such that portion 1463 conforms to the radiusof curvature of the rotary mold.

FIG. 35F is an enlarged view of the region where the conveying surfacecontacts the molded food product. Downstream from the idle roller 1465,the conveying surface 1460 curves in accordance with the radius ofcurvature of the rotary mold to allow the molded food product to be indirect contact with the conveying surface 1460 when initially subjectedto a vacuum force. A vacuum force is exerted on the mold patty as themold patty increasingly makes contact with the conveying surface 1460.

The vacuum chamber comprises a first side wall 1471 and a second sidewall 1472 downstream of the first side wall 1471. The first side wall iselongated such that it is taller than the second side wall 1472, andcurves at the upper portion 1473 to assist in maintaining the radius ofcurvature of the conveying surface 1460. The conveying surface 1460maintains its radius of curvature for a portion 1475 of the gaspermeable layer 1490 as a result of the conveying surface's dispositionon the curved top surface of the vacuum chamber. The gas permeable layer1490 is shaped accordingly with a decreasing thickness in the downstreamdirection for a portion 1475 of the gas permeable layer 1490 on the topsurface of the vacuum chamber to maintain the radius of curvature of theconveying surface 1460. The remainder of the gas permeable layer may beof constant thickness. The gas permeable layer 1490 may be made fromsintered metal, polymeric material, ceramic, or any other suitablematerial. The gas permeable layer 1490 may also be a plate comprising aseries of channels or other openings. The other openings or perforationson the top of the vacuum chamber can be arranged as holes, slots, or anyother suitably sized and shaped arrangement which allows for passing ofair therethrough and the vacuum force to be exerted.

The conveying surface can be a porous belt which allows the vacuum forceto be exerted on the molded food product through the conveying surface.The porous belt maybe made of polytetraflouroethylene (PTFE), or anyother suitable polymeric material or a combination thereof. The porousbelt may be a 0.010 porous PTFE endless belt, or any belt with asuitable porosity. Other belt surface materials with desirable gaspermeability can be used. Alternatively, the conveying surface cancomprise of perforations, or comprise of belt strips to allow the vacuumforce to be exerted on the molded food product.

In one embodiment (FIG. 60) a vacuum chamber 1480 arranged below aporous conveying surface 1460 moving underneath a rotary mold 1452 has aflat top surface 1490 a that is gas permeable. The flat top surface 1490a is in contact with the rotary mold. The conveying surface is endlesslydriven between at least two rollers 1456 a, at least one of which is adriving roller. Alternatively, one of the rollers 1456 b can be thedriving roller. Both rollers 1456 a are raised above the top of thevacuum chamber 1480 such that the portion of the conveying surfacebetween the two rollers is curved about the rotary mold.

In another embodiment (FIG. 61) the vacuum chamber 1480 a has a curvedtop surface 1490 b that is convex to provide additional clearance suchas for when thicker food products are being produced. The porousconveying surface 1460 is disposed over the convex vacuum chamber 1480 aand supported on either end by a roller 1456 a. The rollers 1456 a oneither end of the conveying surface are arranged in a position tomaintain a radius of curvature of the conveying surface that correspondsto the curvature of the vacuum chamber.

In an alternate embodiment (FIG. 62), the porous conveying surface 1460is disposed over a roller 1456 a on one end and a vacuum roll 1481 onthe opposite end. The vacuum roll 1481 comprises a vacuum chamber 1480that is disposed on the vacuum roll 1481. The vacuum roll is a drivenvacuum roll. The vacuum roll may be driven such that the timing ofrotation of the vacuum chamber coincides with each arrival of a filledmold cavity. In one embodiment, the leading edge of the mold cavitymakes contact with the vacuum chamber when it has rotated to its lowestposition on the rotary mold. The circumferential width of the vacuumsurface may be the same or different size as the width of a mold cavity,or the width of the vacuum surface may be larger or smaller than thewidth of a mold cavity.

In another embodiment (FIG. 63) the vacuum chamber is disposed below therotary mold and can pivot in and out of contact with the rotary moldabout a pivot point 1482. The vacuum chamber may be any of the vacuumchambers described above, having a flat, concave, or convex gaspermeable top surface. A poppet valve 1483 can be used to close off theconnection between the vacuum chamber 1480 and a vacuum source 1485 topreserve the vacuum when the vacuum chamber is pivoted out of contactfrom the conveying surface 1460.

Any other combination of arrangements of curved or flat vacuum chamberswith conveyor belts disposed between rollers known to one skilled in theart can be used to achieve the desired removal effect of a molded foodproduct.

FIG. 57D illustrates an alternate embodiment for a system of removingmolded food products from the cavities of a rotary mold. An air impactsystem or “air knife” system 5000 as illustrated in FIG. 57D comprisesan elongated air nozzle or air knife 5030 mounted to the mandrel 5010 ofthe rotary mold cylinder. The air knife 5030 is secured to a supportbracket 5020 by at least one bolt 5021 a. Bolt 5021 b secures thesupport bracket 5020 to the mandrel 5010. As illustrated in FIG. 58, theair knife 5030 comprises two members 5032 and 5031 connected to eachother by way of screws such as screw 5033. The air knife has an inletmember 5031 which houses an inlet 5050 to receive a source ofpressurized air flow. The air knife has a nozzle member 5032 which whendispose in contact against the inlet member 5031, forms a longitudinallyslotted nozzle 5060 for at least a portion of the length of the airknife 5030. In some embodiments the slotted nozzle 5060 may extend forthe entire length of the air knife 5030. The air knife may be anysuitable air knife, or can be an air knife such as the SUPER AIR KNIFE™manufactured by Exair Corporation, located in Cincinnati, Ohio. The airknife may be made of stainless steel, or any other alloys, or anysuitable metals, or any other suitable material can also be used. Thenozzle may be a slit 0.002 inches wide, or the nozzle may be wider ornarrower depending on the desired airflow dynamic.

The air knife 5030 provides a sheet of airflow 5070. In one embodimentthe sheet of airflow is a uniform sheet of air across the entire lengthof the air knife. The air knife is arranged such that the air flow isdirected in a downwards direction, towards molded food products 5080within a mold cavity which has rotated to the eject position. The sourceof airflow can be compressed air, or any suitable gas which can flow outof the nozzle at a sufficient rate to generate a force to remove thefood product from its mold. The sheet of airflow is of a sufficient sizeto span the width of a row of mold cavities. Multiple air knives may beconnected end to end to achieve the desired air flow sheet size.

FIGS. 57A-57C illustrates the process of removing a molded food productusing the air knife. FIGS. 57A-57C illustrate the progression of thefood product 5080 removal as the mold rotates about the stationary airknife 5030. Molded food product 5080 has a leading edge 5081 and atrailing edge 5082. The leading edge 5081 of the food product firstcomes into contact with the sheet of airflow 5070 which provides enoughforce by impact of the air stream to dislodge the leading edge 5081 ofthe molded food product from the mold cavity. As the rotary mold turns,the sheet of airflow dislodges the molded food product starting from theleading edge 5081 end towards the trailing edge 5082 end. As the portionof the molded food product becomes dislodged from the mold cavity, thedislodged portion of the molded food product becomes disposed on to aconveying surface. In the embodiment illustrated in FIGS. 57A-59, theconveying surface is in tangential contact with the rotary moldcylinder. In other embodiments, the conveying surface may be below therotary mold cylinder such that there is space between the conveyingsurface and the molded food product.

In one embodiment, the air knife system 5000 can be used in combinationwith any of the systems of removing molded food products describedabove, wherein the rotary mold rotates over a conveying surface having avacuum force disposed below the conveying surface. In the embodimentillustrated in FIG. 59, a porous conveying surface 1460 is disposed intangential contact with the surface of the rotary mold. A vacuum chamber1480 disposed beneath the conveying surface 1460 has a gas permeable1490 on the top surface of the vacuum chamber which is flat. The flatgas permeable layer 1490 supports the conveying surface 1460 to maketangential contact with the surface of the rotary mold. An idle roller1465 is disposed on one end of the endless conveying surface 1460 andsupports the endless conveying surface. In the embodiment illustrated inFIG. 59, the air knife system 5000 is used to exert a downward forcefrom within the mold cylinder to push the molded food product from themold cavity, while the molded food product, as it makes contact with theporous conveying surface disposed over the vacuum chamber, is pulleddownwards onto the conveying surface by the vacuum force.

In other embodiments, the vacuum chamber may have a curved—convex orconcaved—top surface for providing contact with the mold cavity, and maybe positioned along the conveying surface at various positions withvarious configurations of the conveying surface.

Rotary Mold for Forming Contoured Products

FIG. 36 illustrates an alternate embodiment of a rotary molding systemfor forming contoured food products such as a food product shaped like adrumstick illustrated in FIG. 41. The invention is not limited to thisshape, or even to the shape of an identifiable food item, and insteadcan be any shape which may have consumer appeal. The rotary moldingsystem comprises a fill plate 1760, the rotary mold 1900, and the wearplate 1770. The fill plate 1760 and wear plate 1770 is in contact with aportion of the rotary mold 1900 defined by the intersection of an angle“a” with the rotary mold 1900, as illustrated in FIG. 19. The angle “a”may be 120 degrees.

FIG. 36 illustrates perspective cross sectional view across a set ofmold cavities 1910 while the mold cavities are between the fill plate1760 and the wear plate 1770. The rotary mold 1900 includes alternatingflat plate regions 1082 and shaped regions 1086. The shaped regions 1086extend circumferentially and are shaped to resemble the cross section ofan identifiable food product, for example, a drumstick. FIG. 39illustrates a cross section of the mold cavity 1910 and a portion of theflat plate regions 1082 and the shaped regions 1086. FIG. 40 illustratesa cross section of the shaped regions 1086, with the flat plate regions1082 on either side. The rotary mold has a shaped region which protrudeson both the fill plate side and the wear plate side of the rotary mold.

As shown in FIGS. 36 and 37, the fill plate 1760 on the surface thatcomes in contact with the rotary mold, has a contoured surface thatextends circumferentially for the entire portion of the fill plate incontact with the rotary mold, which has a shape conforming close to thecontours as defined by shaped regions and flat regions of the rotarymold. In a similar fashion, the wear plate 1770 on the surface thatcomes in contact with the rotary mold, has a contoured surface thatextends for the entire portion of the wear plate in contact with therotary mold, which has a shape conforming close to the contours asdefined by the shaped regions and flat regions of the rotary mold.

As shown in FIG. 36, each shaped region 1086 or the rotary mold 1900contains several cavities arranged along the circumference of the rotarymold. Although three rows of shaped regions 1086 are shown, any numberof rows are encompassed by the invention. The cavities can be instaggered rows, or straight rows. The cavities 1910 have an irregular orcurved profile as illustrated in FIG. 36. The profile is curved tosimulate a chicken drumstick. Other shaped cavities can be used.

Fill plate 1760 and any breather or vacuum regions as discussed above,includes the contoured surfaces as illustrated in FIGS. 36 and 37, whichadapt to the flat plate regions 1082 and the shaped regions 1086 of therotary mold 1900. The fill plate 1760 includes a contoured surfacehaving flat areas 1182 that correspond in position to the flat plateregions 1082 of the rotary mold, and recessed areas 1186 that correspondin shape to the shaped regions 1086 of the rotary mold.

Wear plate 1770 comprises a contoured surface as illustrated in FIGS. 36and 38. The contoured surface includes flat regions 1282 and recessedregions 1286 which correspond to the flat plate regions 1182 and shapedregions 1186 of the rotary mold.

FIG. 42 illustrates the feeder portion 1700 of a rotary molding systemwhich can be used with the rotary mold for forming contoured products.The feeder portion comprises a feeding channel 1710 within a feed plate1703. The feed plate 1703 comprises a curved portion 1705 which isadapted to complement the curvature of the rotary mold 1900.

The food product enters the feeding channel 1710 at a feeding channelinlet 1706 located generally in the central region of the feed plate1703 as illustrated in FIG. 42. From the channel inlet 1706, the foodchannel 1710 gradually fans out to a length corresponding approximatelyto the distance spanned by a longitudinal row of mold cavities, toensure delivery of food product to all mold cavities within alongitudinal row. The feeding channel 1710 has a frustoconical crosssection, as illustrated in FIG. 42, which assists in graduallyincreasing the pressure of the food product as the food product movestoward the rotary mold for injection into mold cavities 1910.

A feeding channel adaptor 1704 is used to connect the feeding channel toa source of pumped food product. Food product is moved into the feedingchannel 1710 from a food hopper 1701 using a pump 1702 as discussedabove with respect to the previous embodiment of the invention, andillustrated schematically in FIG. 42.

The fill plate 1760, as illustrated in FIGS. 36 and 42, is a curvedplate disposed in contact with the curved portion 1705 of the feed plate1703. The fill plate 7160 is disposed between the rotary mold 900 andthe feed plate 1703. The fill plate 1760 comprises a feeder inletpassage 1720 through which the food product passes to enter the moldcavities 1910.

The mold cavities 1910 within the rotary mold 1900 provide the contoursof the side 1911 of the molded food product (FIG. 41). To form a moldproduct with the contoured top surface 1912 and bottom surface 1913, amold cavity with three dimensional contours is formed within the regiondefined by the mold cavities 1910, the contoured surface of the fillplate 1760 and the contoured surface of the wear plate 1770. A feederinlet passage 1720 for each three dimensional contoured mold cavity canbe used, or the feeder inlet passage may span a length corresponding tothe length spanned by a row of mold cavities. Other arrangements for afeeder inlet passage, include those discussed previously, can be used.

As illustrated in FIG. 42, once the filled mold cavity leaves the fillstation and exits from between the space formed between the fill plateand the wear plate, the top and bottom surfaces 1912, 1913 of thecontoured mold product are exposed. The contoured mold product issupported by the side walls of the mold cavity. Once the contoured moldproduct is in an eject position under the knock out mechanism, knock-outcups shaped to complement the contours of the top surface 1912 are usedto remove the molded food product from the mold cavity.

FIG. 41 illustrates a completed molded food product. The productincludes a contoured top surface 1912 being curved in the horizontal aswell as the vertical place, a contoured bottom surface 1913, also beingcontoured in the vertical and horizontal planes, and contoured sidesurfaces 1911 which are contoured in the horizontal plane.

Various knock out mechanisms 1800 (FIG. 42) may be used with the rotarymold 1900. Knock-out mechanism can utilize an air pressure region whichexerts a force sufficient to eject the food product from the mold.Pressurized air can be transported to the air pressure region via airchannels, or a piston within the air pressure region is actuated toextend rapidly from a retracted position to generate air pressure. Theend of the piston may be a knock out member shaped to correspond to theshaped regions of the rotary mold such that the piston may extend to aposition close to the molded food product than would be possible with anon-contoured knock-out member. The use of knock out cups which comeinto contact with the food product may also be used. The knock out cupswill have an identical, albeit slightly smaller, outside perimeter suchthat the knock out cups can pass downwardly into at least a portion ofthe mold cavities to remove the molded product within. The knock-outcups include a bottom surface which conforms to shape to the shapedregion 1086 of the rotary mold. In one embodiment, the knock out cupsare mounted to a knock out assembly described with respect to FIGS.19-21 and 25. Other knock-out mechanisms may be used.

In operation, the contoured mold cavities are filled in their fillposition and rotate counterclockwise to the eject position. As theyrotate toward the eject position, the molded food product rotates outfrom between the fill plate and the wear plate which formed the moldcavity surface on either side of the rotary mold. As the molded foodpatty is rotated away from the fill position by the rotary mold, themolded food patty has exposed surfaces extending from the rotary moldcavity on either side.

FIGS. 43 and 44 illustrate an alternate embodiment of the rotary moldfor forming food products with a beveled edge. Such contoured foodproducts which comprise two flat surfaces 1511, 1512 and a beveled sideedge 1513 can be made with the rotary mold as illustrated in FIG. 44.FIG. 44 is a longitudinal cross sectional view of the rotary mold. Moldcavity opening 1521 on the inner surface 1501 of the rotary mold isillustrated in solid lines while mold cavity opening 1522 on the outersurface is illustrated in dashed lines. The beveled edge 1513 a of themold cavity allows for a continuous connection of the mold cavityopenings 1521 and 1522. The mold cavities 1520 in FIG. 44 are contouredin the vertical and horizontal planes. Because the resulting molded foodproduct is flat on both surfaces 1511 and 1512, a mold cavity entirelycontained within the thickness of the rotary mold suffices to producethe desired product. The portion of the fill plate and wear plate incontact with the rotary mold at the fill station are flat. Any of themechanisms described above can be used to remove the product. If aknock-out cup is used, the knock out cup should be shaped to fit withinthe mold cavity opening 1521.

From the foregoing, it will be observed that numerous variations andmodifications may be effected without departing from the spirit andscope of the invention. It is to be understood that no limitation withrespect to the specific apparatus illustrated herein is intended orshould be inferred.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the extentthat the references are not inconsistent with the present disclosure andto the same extent as if each reference were individually andspecifically indicated to be incorporated by reference and were setforth in its entirety herein.

1-45. (canceled)
 46. A rotary mold system for molding three dimensionalfood products from a food mass comprising: a fill plate having an outersurface in contact with a feed source, and an inner surface; a wearplate having an outer surface facing the inner surface of the fillplate; a cylindrical mold shell with mold shapes, the mold shell havingan inner and outer surface, said mold shell rotating between the fillplate and the wear plate, the fill plate in contact with the outersurface of the mold shell, the wear plate in contact with the innersurface of the mold shell; mold cavities formed when mold shapes arebetween the interface plate and the wear plate, said mold cavitieshaving a depth corresponding to the thickness of the mold shell, andsaid mold cavities having a bottom surface formed by the outer surfaceof the wear plate; and a vacuum chamber disposed below the mold cavityfor removing molded food product from the mold cavity.
 47. The moldsystem of claim 46 wherein a conveying surface is disposed over thevacuum chamber, the vacuum chamber connected to a vacuum source, theforce of vacuum exerted through the conveying surface onto the moldedfood product to remove the food product from its mold.
 48. The moldsystem of claim 47 wherein the conveying surface is a porous surface.49. The mold system of claim 47 wherein the conveying surface has atleast a portion which is curved; said curved portion corresponding tothe curvature of the rotary mold.
 50. The mold system of claim 49wherein the conveying surface is in contact with a portion of the rotarymold.
 51. The mold system of claim 50 wherein the vacuum chamber has atop surface which is perforated to allow negative pressure to pass; atleast a portion of the said perforated top surface is contoured toconform to the curvature of the rotary mold.
 52. The mold system ofclaim 50 wherein the conveying surface is an endless conveyor belthaving a driving end and an idle end; said idle end being supported byan idle roller which is sized and located relative to the vacuum chambersuch that the points of contact between the idle roller and the surfaceof the mold, and between the vacuum chamber and the surface of the moldallows a portion of the conveying surface supported between the idleroller and the vacuum chamber to conform to the curvature of the rotarymold.
 53. Method of removing molded food products from a mold cavity ona rotary molding apparatus, comprising the steps of: providing aconveying surface disposed in moving contact with the rotary mold; saidconveying surface supported by an idle roller and a vacuum chamberdisposed below the conveying surface, said conveying surface has aportion that is curved to correspond with the curvature of the rotarymold at the portion the conveying surface makes contact with the surfaceof the rotary mold; providing a vacuum within the vacuum chamber to beexerted on the molded food products from a position below the moldedfood product to remove the food product from its mold cavity.
 54. Themethod of claim 53 wherein the mold cavity has a leading edge and atrailing edge, the leading edge rotating first into contact with thevacuum, the vacuum being exerted on the leading edge and gradually overremaining regions of the food product towards the trailing edge of themold cavity as the rest of the molded food product gradually comes intocontact with the vacuum.
 55. The method of claim 53 wherein the step ofproviding a vacuum comprises the step of passing negative pressure fromthe vacuum chamber through the conveying surface, said conveying surfacebeing porous.
 56. The method of claim 53 wherein the step of providing aconveying surface comprises the step of providing a curved conveyingsurface portion; and wherein the vacuum chamber has a top surface curvedto correspond to the curvature of the rotary mold over which the curvedconveying surface portion is disposed.
 57. Method of removing moldedfood products from a mold cavity disposed on the surface of a rotarymold comprising the steps of: providing a source of negative pressuredisposed below the mold product at its eject position; exerting thenegative pressure on the lower surface of the mold product to remove themolded product from its cavity.
 58. Method of 57 further comprising thestep of providing a conveying surface between the molded food productand the source of negative pressure to support molded food product as itis removed.
 59. The method of claim 57 wherein negative pressure isexerted beginning at one end of the food product and gradually towardsthe rest of the food product as the mold rotates.
 60. The method ofclaim 59 wherein the rotation of the mold cavity exposes the moldcavities to a stationary source of negative pressure.
 61. The method ofclaim 57 wherein removed food products are conveyed away from the sourceof negative pressure and rotary mold.
 62. The method of claim 58 whereina portion of the conveying surface is supported in contact with therotary mold apparatus by the source of negative pressure. 63-144.(canceled)
 145. A mold system for molding three dimensional foodproducts from a food mass comprising: an fill plate having an outersurface in contact with a feed source, and an inner surface, said fillplate having a feed inlet through which food mass passes; a wear platehaving an outer surface facing the inner surface of the fill plate; acylindrical mold shell with mold shapes, the mold shell having an innerand outer surface, said mold shell rotating between the fill plate andthe wear plate, the fill plate in contact with the outer surface of themold shell, the wear plate in contact with the inner surface of the moldshell; mold cavities formed when mold shapes are between the fill plateand the wear plate, said mold cavities having a depth corresponding tothe thickness of the mold shell, and having the outer surface of thewear plate as the bottom surface of the mold cavity when the mold cavityis in communication with the feed inlet at the fill position, said moldcavities having a bottom surface formed by the outer surface of the wearplate; and a vacuum region disposed on the fill plate upstream of thefood inlet for removing air from the mold cavities.
 146. The mold systemof claim 145 wherein the vacuum region is in communication with a vacuumsource.
 147. The mold system of claim 146 wherein the vacuum source is avacuum pump.
 148. The mold system of claim 145 wherein the vacuum regionis communication with lower pressure regions of the mold system. 149.The mold system of claim 145 wherein the mold cavity has a width; andwherein the vacuum region and the feed inlet are arranged to be spacedapart by at least the width of the mold cavity such that the vacuumregion and the feed inlet are not simultaneously in communication withthe mold cavity.
 150. The mold system of claim 145 wherein the moldcavity has a width; and wherein the vacuum region and the feed inlet arearranged to be spaced apart by less than the width of the mold cavitysuch that the vacuum region and the feed inlet can be simultaneously incommunication with the mold cavity. 151-206. (canceled)